Thermostat having modulated and non-modulated provisions

ABSTRACT

A thermostat providing modulated or analog control of valves or dampers of an air management system. This permits operating a single cooling or heating stage with partially open valves or dampers as needed, since one full stage that is either fully on or off may not be easy to manage for effective air management of a particular type of building, zone or facility. The thermostat may also provide non-modulated control of multi-stage cooling and heating systems. The thermostat may even be used to control a modulated system having more than one stage of cooling or heating.

The present application is a Divisional of U.S. patent application Ser.No. 10/643,376 filed Aug. 18, 2003.

BACKGROUND

The present invention pertains to thermostats and particularly to thecontrol of air management systems. More particularly, it may pertain toprogrammable thermostats providing modulated and non-modulated controlof air management systems.

Air management systems that have several stages of cooling and heatingdo not function particularly efficiently, inexpensively, or providecomfort with ease. It may be that one stage provides too much cooling orheating. If the stage could be operated at partial capacity, there wouldbe flexibility of control that could benefit smaller buildings and thepossibly smaller businesses that may reside in them. The presentthermostat has a way of minimizing these issues and may do so with amodulated or analog control of the system. Also, the same thermostat mayutilize staged cooling and heating as needed.

The setting and adjusting of air management system thermostats,especially programming thermostats, to control air conditioning,heating, humidity, volume of moved air, and the like, may have settingsand conditions that determine which equipment is modulated, turned on oroff, and for when and what duration. Many commercial and residentialplaces may have complex and confusing controls for air managementsystems which have features such as programmable thermostats. Someproprietors may obtain a programmable control system for controllingheating and cooling in their buildings. However, they may havefrustrations with the adjusting and operating those kinds of systems andoften stop trying to take advantage of certain control features of thesystems. An installer may initially set a system up and get it operatingsatisfactorily; however, the adjusting and setting the system may not beeasy for the new recipient or owner of the system because of theapparent complexity, user unfriendliness, and the lack of convenient andsufficient time to learn, set and adjust various parameters of thesystem for controlling, for instance, heating, ventilation and airconditioning (HVAC).

SUMMARY

Programmable commercial thermostat systems have been gaining inpopularity due to the energy savings associated with programmableschedules and set points. Most small commercial buildings with one ortwo zones typically may have rooftop equipment controlled through relaycontacts such as heat stage 1, heat stage 2, cooling stage 1, coolingstage 2, and fan. These controls may be interfaced through remote wiringfrom the zone thermostat to the associated rooftop unit. As commercialthermostat requirements and thermostats become more sophisticated, theremay be a need to control heating and cooling coils at control ranges inbetween specific stage loads. This could be particularly important aschilled water systems and partial load or oversized systems are used.Further, there appears to be a need to control modulating zones and aneed for a commercial modulating thermostat that is able to support bothtraditional staged and modulating outputs.

This invention may solve the problems associated with control issues byimplementing a true analog heating and cooling signal to be implementedby the roof top control system. Several enhancements and options existin the algorithm and thermostat configuration to assist and lead tocontrol of water valves and oversized heating coils and loads. Understaging conditions, traditional control algorithm techniques may be usedto control the on/off control to the heating coils, cooling coils andfan. When used in a modulating configuration, special analog drivercircuits may allow the output from the thermostat to provide 4 to 20milliamps and 2 to 10 volts for direct interfacing for the control ofmodulated components. These control parameters are popular ranges formany modulated dampers and valves used in air management systems, suchas HVACs.

The thermostat may contain a software component that allows automaticconfiguration of the output actuation type (modulation and discrete)identified by the sub-base with preset configuration resistors. Thehardware component of the output actuation may be implemented through ananalog interface set from the thermostat. Analog control and interfaceto the modulation may be controlled through software algorithm PID andstaging information. If additional heating is desired after a stage isadded at low load, additional supply is available through increasing ofthe analog heating signal. Applications of this modulating thermostatmay be used for boiler firing rate controls and other energy supply orcooling type equipment. Through the use of programmable memory,additional algorithms can be developed to apply to a wide range andvariety of control applications besides air management system control.

The present thermostat may provide modulated/analog control of an airmanagement system and discrete/digital control of the same or anotherair management system. This thermostat may provide modulating control ofa single stage of heating and/or cooling. On the other hand, thisthermostat may provide modulating control of multiple stages of heatingand cooling. The modulating output to one cooling or heating stage mayresult in an efficient level of output of the controlled stage. If moreoutput is needed from that stage, the thermostat may with the modulatingoutput call on another stage and control it for more heating or cooling,so as to maintain the better efficiency of the first stage. Also,modulated control may result in the next stage's approaching anefficient level of output. This approach may continue for more output orless output as needed form the respective stages. The thermostat mayprovide analog or digital signals for controlling single or multiplecooling or heating stages. Humidity control may also be implemented bythe thermostat and associated air management equipment. A group ofthermostats may be connected to a common communications bus. Such busmay have a sequencer connected to the bus. Instructions, softwarechanges, commands, parameters and other information may be communicatedamong the thermostats and the sequencer. Operations of the thermostatsmay be sequenced.

The thermostat system may minimize the issues of complexities, userunfriendliness, and the amount of time and convenience involved insetting up, adjusting and controlling an air management system, such asan air handling and conditioning system. The system makes it possiblefor one at a convenient time at any place to set and adjust athermostat, controller or computer having numerous parameters andoptions that may be selected for a desired operation of the airmanagement system. One does not need to be at the thermostat, controlleror computer of the air management system to configure, set or adjust theparameters of it. The parameters may include, but not be limited to,temperatures, humidity, sensor selection, volume of air movement, fan orair mover behavior such as continuous or intermittent and speed, thepercentage of added fresh air, stages of cooling and heating at variouszones, control of heat pumps, heaters and air conditioners, modes ofoccupied, unoccupied or standby of respective spaces in a building, forday and night, between specific times, at certain days, for certainbuildings at specific locations. The system may easily enable one toeasily and conveniently achieve these tasks with an interfacing of a PDA(viz., a personal digital assistant) to the control system. These tasksmay be accomplished on a PDA in an armchair remote from the facilitywith the air management system.

A program with configuration information may be uploaded to the PDA froma controller of an air handling and conditioning system, such as theHVAC. Such controller may be similar to a programmable thermostat havingadjustment and settings for controlling the parameters of the system.All of the items that need to be done for configuring, setting,adjusting and controlling a system via the thermostat, controller orcomputer may be done on a PDA at any time at a location as desired,possibly remote from the building having the system. Whether at theoffice, home or other place, one may configure, set and adjust, amongother things, with the PDA, parameters and actions of a controllerrelative to various air management systems at different facilities.Programmed configurations, settings, adjustments and the like may bedone with the PDA. Then one may take the PDA and go to the variousthermostats, controllers, computers or other air management systemcontrol devices and upload the programs specific to the respectivesystems. These may be placed in memory. One interface connection for theuploading and downloading between the PDA and the thermostat, controlleror computer of the air management system may be an infrared (IR)connection. One may obtain a PDA that is readily available in stores,such as a Palm™, or the like, and take it to a thermostat, controller,computer or control module of the air management system and upload aprogram, including the configuration and the settings the system. Thenone may deal with various configurations, settings, adjustments andrelated activities as desired relative to the parameters of the airmanagement system and then download any changes to the respectivethermostat, controller, computer or control module of the system.

The interfacing between the PDA or similar commercially available deviceand the controller or thermostat may also be done via radio frequencycommunications (such as Bluetooth or Wi-Fi), electrical lines such asthe telephone, or optical fiber systems. The internet, Ethernet, orintranet in its various aspects may be used for interfacing between thePDA and the controller or thermostat. Other forms of interfacing betweenthe PDA and the system may be implemented.

A technical person, installer, representative or technician, trained forconfiguring, setting and adjusting control mechanisms of air managementsystem thermostats, may go to various buildings such as stores,factories or offices and do control changes for the air managementsystems of those places. The control mechanism of the air managementsystem of each place may have its own specific configuration andsettings which may be different from the others. The technician may gofrom place to place and download specific configurations and settingswith the PDA very quickly and efficiently to the air management systemthermostats at these places.

Even though there are many ways that programmable thermostats,controllers, control mechanisms, computers, control modules or theirequivalents (hereinafter each of these may be referred to as a“thermostat”) of air management systems may be communicated with,relative to the setting and configuration inputs, the PDA using theinfrared interface is inexpensive and easily adaptable. Many individualshave a PDA of one kind or another which may have an infrared or directconnection port. No modification is of these devices needed to use themwith the system. One merely may go to the respective thermostat of thesystem and upload a program that has the appropriate protocol,configuration and setting information of the system. Then one may enterthe desired settings, adjustments and schedule information relative tothe control of the air management system. The information is presentedon the PDA in a clear and step by step instructive manner. And asindicated above, the PDA may contain numerous and differingconfigurations and settings applicable to specific systems at differentplaces. Anyone with a PDA or the like may participate in this program.However, there may be security measures requiring codes or otherpermission granting procedures so that the integrity of the control ofair management systems may be maintained.

An installer's configuring of high end programmable commercialthermostats has become very complex due to all of the features that canbe implemented by low cost microprocessors. There is a trade-off betweenthe ease of use and the complexity of the user interface. Configuringmight be done only once by the installer and then usually is notrequired again for the life of the thermostat, whereas for settings andadjustments, the operator interface may be used periodically and shouldbe as user friendly as possible. In the past, the installerconfiguration process was very obscure and error prone since it had beena secondary function of the operator user interface that partiallyreused some of the operator interface features in an obscure secondarymanner so as to attempt reducing costs associated with the device. Thisapproach was time consuming and error prone, had to be repeated for eachinstallation, and was still costly.

By removing the thermostat configuration installer interface from thethermostat operator interface to a PDA, as in the present system, thefollowing benefits are noted. There is an easy to use configurationprocess with context checking on previous selections so only validoptions are presented and errors cannot be made, and also easy to usenavigation of thermostat configuration screens. Novice users may bedirected to the next appropriate parameter entry screen based on thecontext of previous configuration selections. Configurations can be doneahead of time and downloaded quickly at installation time. Similarconfigurations do not have to be repeated on every device but simplyrecalled from storage and downloaded. The PDA based thermostatconfiguration application may generate a code that represents the rawconfiguration. This code can be recorded (for example on paper) andentered by hand quickly into the thermostat keyboard if a PDA is notavailable at the job site. There is context dependent control looptuning. The thermostat PID (viz., proportional, integral and derivativegains) control loop tuning parameters may be automatically adjusted as afunction of equipment type, number of output stages, output type(modulating or discrete), the HVAC process, and other factors asdesired.

A PDA and its interfacing with the thermostat of an air managementsystem may also be used for automatic testing, checkout, analysis anddiagnosis of the system. Testing and trouble-shooting a complex fullyfeatured commercial thermostat may be time consuming and confusing sincethe configuration must first be understood and then the operation mustbe run through valid modes with inputs and set points temporarilymanipulated, plus waiting for the delays built into the controller, toverify operation.

Commissioning a complex fully featured commercial thermostat also may betime consuming and confusing. The thermostat configuration should firstbe understood and then the commissioning process may be run throughvalid operational modes with inputs and set points temporarilymanipulated while waiting for the delays built into the controller toverify operation.

The PDA based online diagnostics may automatically discover thethermostat configuration, turn off normal controller delays, temporarilyoverride sensor inputs and set points, verify proper output actionincluding monitoring the discharge air temperature for the resultingtemperature behavior based on the equipment stages activated. Problemsdiscovered may be reported, automatically recorded and the originaloperating parameters may be restored. This means that less expertise maybe required by the technicians sent to install and trouble shootthermostat installations.

A thermostat may be designed to interface to a PDA or other handy lowcost device with an easy wire, IR or RF connection that will allow it dofast, accurate automatic thermostat testing, diagnosing andtrouble-shooting. The PDA may automatically obtain the thermostatconfiguration, turn off normal controller delays, temporarily overridesensor inputs and set points, and verify proper output action includingmonitoring the entry and discharge air temperatures for the resultingtemperature behavior based on the equipment stages activated. Problemsdiscovered can be reported, automatically recorded and the originaloperating parameters can be restored. This means that less expertise isrequired by the technicians sent to install and trouble shootthermostats. Smart status reporting simplifies the thermostatinstallers' field-commissioning task of selecting and monitoring theappropriate real time data. The smart status report content and layoutmay be based on a theme of management by exclusion. The report generatormay respond to real time parameter and data changes in the thermostatenvironment. There may be a possible web-based system in which theinstaller or technician need not to go out to the site of the airmanagement system. The installer or technician may be able to diagnoseand can fix the system over the internet, Ethernet or the like. However,using the PDA and its infrared interface may be as or more reasonablethan the configuring or diagnosing a thermostat, its sub-base andcorresponding air management system. PDA configuring and diagnostics maybe utilized in residential homes as well as commercial facilities.

Information about an example sequencer may be disclosed in U.S. Pat. No.6,536,678 B2, entitled “Boiler Control System and Method”, issued Mar.25, 2003, and by inventor Michael A. Pouchak, which is herebyincorporated herein by reference. Information about an example humiditycontroller may be disclosed in U.S. patent application Ser. No.10/314,604, entitled “Humidity Controller”, filed on Dec. 4, 2002, andby inventor Paul C. Wacker, which is hereby incorporated herein byreference. Information about an example HVAC may be disclosed in U.S.Pat. No. 5,172,565, entitled “Air Handling System Utilizing DirectExpansion Cooling”, issued Dec. 22, 1992, and by inventors Richard A.Wruck et al., which is hereby incorporated herein by reference.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 shows a configuration tool for a thermostat of an air managementsystem.

FIG. 2 shows the configuration tool of FIG. 1 in conjunction with asub-base.

FIGS. 3 a and 3 b show screens of a personal digital assistant (PDA) forentering a new thermostat configuration.

FIGS. 4 a-4 d show PDA screens for selecting an existing configurationand connecting the PDA to the thermostat for uploading theconfiguration.

FIGS. 5 a-5 c reveal screen for downloading a new configuration to thethermostat.

FIGS. 6 a-6 d are screens that relate to uploading and modifying anexisting configuration, and downloading it.

FIGS. 7 a and 7 b are screens showing a download and upload connectionselection to a thermostat and a room temperature calibrate,respectively.

FIGS. 8 a-8 e are screens showing a process for connecting to athermostat, reading information and saving it, and monitoring data.

FIGS. 9 a-9 j illustrate steps of reviewing the configuration of athermostat, making possible changes and saving them.

FIGS. 10 a-10 l show the screens and steps for an advanced configurationreview, possible modification, and saving of any modification.

FIGS. 11 a and 11 b show screens for selecting units and locking defaultconfiguration files.

FIG. 12 a shows a file command screen.

FIGS. 12 b-12 e are screens that show various actions that may be takenrelative to a configuration.

FIG. 13 relates to setting the time and date of the thermostat beingconfigured.

FIGS. 14 a-14 m are screens showing steps for scheduling varioustemperature set points on different days, selecting fan operation,selecting heating and cooling stages, selecting sensor location, loadingthe program for a particular facility and saving the current thermostatconfiguration.

FIGS. 14 n-14 r are screens relating to the enabling of partialdownloads after the opening screen.

FIGS. 14 s-14 z are screens pertaining to various override options.

FIG. 15 is a flow chart of formation and downloading contractorinformation to a thermostat.

FIG. 16 is a diagram showing the major components and communicationchannels of the thermostat.

FIG. 17 is a block diagram of a modulating thermostat system.

FIG. 18 is a block diagram of a networked modulating and non-modulatingthermostat system.

FIG. 19 is a flow diagram of a modulating sub-base sequence.

FIGS. 20 a and 20 b show a display and a thermostat assembly with thedisplay and a keyboard.

FIG. 21 shows a roof top air management system.

FIG. 22 is a context diagram revealing a process structure in athermostat.

FIG. 23 is a diagram of a transmit and handshake portion of acommunications process of the thermostat.

FIG. 24 shows an overview of an algorithm mode relative to thethermostat.

FIG. 25 shows details of a function in the algorithm shown in FIG. 24.

FIGS. 26 and 27 reveal the various connections between the thermostat,sub-base and an external device such as a PDA.

FIGS. 28 a-28 c show PDA screen steps to attain a commission summaryscreen of a test and diagnosis of a thermostat system.

FIGS. 29 a-29 f show screens for a diagnosis of temperature and othersensors, and set points.

FIG. 30 is a screen for a fan check.

FIGS. 31 a-31 h are screens showing steps for cooling equipment testingand diagnosis.

FIGS. 32 a-32 e show PDA screens for testing heating equipment of thethermostat system.

FIG. 33 is a flow diagram of an illustrative diagnostic test sequencefor a thermostat system.

DESCRIPTION

The system may include an installation and/or configuration tool 10 fora programmable thermostat 11, or the like, of an air management system15, as shown in FIGS. 1 and 2. Thermostat configuration tool and system10 may consist of application code and two hardware devices. A PDAapplication code may be used to configure the thermostat. The firsthardware device may be a tool platform 12, that is, a PDA hand helddevice. The second device may be an RS232 interface module 13 includinga connection cable. Sensors 25 may be connected to thermostat 11.Configuration tool and system 10 may provide the following value addedfeatures: an armchair thermostat 11 setup; a saving of tested thermostatconfigurations for reuse; a reduction of configuration errors; areduction in warranty returns and customer callbacks; an updating ofcontrol setpoints (for example room temperature occupied, unoccupied andstandby setpoints); weekly and holiday schedules; and user defineddefault configuration values. A PDA hardware platform is preferred overa laptop personal computer (PC) 24 for several reasons including, butnot limited to, lower initial cost and smaller size.

An illustrative example of thermostat 11 may be a prototype programmablethermostat, model T7350, built by Honeywell International Inc. inMinneapolis, Minn. The configuration tool 12 application software and a10 pin serial interface module may be compatible with the following PDAhardware platforms: Palm™ m105; Palm™ m100; Palm™ Vx Series; Palm™ VIISeries; Palm™ III Series; Palm™ i705; Palm™ Zire71; Palm™ TungstenT; andTRGPro™. The application code may be compatible with PALM OS™ softwareversion 3.5.x. “OS” is an operating system of a Palm™ platform. The OSversion compatibility may be for all versions greater than or equal to3.5x, such as OS 5.2.1. The system may also be hosted on a MicrosoftWindows™ CE OS PDA platform. Configuration tool serial interface 13module may be compatible with the various models and versions ofthermostat 11. The thermostat serial interface module may support IR,WiFi, Bluetooth and other wireless communications media. Thermostat 11may have serial communications to allow communications with installerconfiguration tool 12 and a sub-base 14. Thermostat 11 may be configuredusing an installer setup through the thermostat keys 15 for basic setupfunctions. Advanced features may be available through installerconfiguration tool 12.

Thermostat configuration tool 12 may be used in the context of thefollowing scenarios. In configuring offline, the user may arrange andsave various named thermostat configurations with tool 12 disconnectedfrom the thermostat 11. The user may have the option to note aconfiguration identification code and manually set the code using toolor user interface 12. Then interface 12 may connected to a thermostat 11and air management system 15 may be configured with an existing namedarrangement of parameters. Configuration tool 12 may read and verify theexisting arrangement of parameters. Virtually all of the parameters maybe changed resulting in a modified or new configuration. Also, thetemperature display of thermostat 11 may be calibrated. The user mayhave an option to save the modified or new configuration file underanother name.

Tool 12 may be utilized for performing online diagnostics. For example,tool 12 may be connected to thermostat 11 and diagnostic informationsuch as the thermostat firmware version, the thermostat hardwareversion, the sub-base hardware version, and run time error messages maybe read.

The thermostat configuration tool 12 may have a configuration which mayinclude third party PDA hardware platform supporting applicationsoftware and serial connection cable with the RS232 interface of module13. The Palm™ PDA, as an illustrative example, may be used inconjunction with the serial interface having connections as noted in thefollowing table 1 showing the terminals for a Palm™ PDA serialconnection.

TABLE 1 Pin # Signal Name & Direction Function 1 DO (out) DTR 2 VCC(out) +3.30 V Palm ™ III through a 330 ohm resistor. +4.07 V Palm ™ V 3RXD (in) Receive Data. 4 RTS (out) Request to send. 5 TXD (out) TransmitData. 6 CTS (in) Clear to send. 7 HS IRQ (in) Interrupt line for wakingthe device, Palm OS ™ default is to initiate the HotSync process. 8 ID(in) Peripheral ID line. 9 unused Not connected 10  SG Signal Ground

One may note that pin 10 is located at left as viewed from the back ofthe Palm™ PDA. The HotSync cradle button shorts pins 2 & 7. Palm™devices i705, m125, m130 m500, m505, m515 require a 16 pin connector.One may refer tohttp://www.palmos.com/dev/tech/hardware/palmhardware/electrical_interface(16-pin)signals.pdffor details regarding the Palm™ 16 pin connector.

Thermostat 11 configuration may be changed or varied according tocertain aspects which are provided as an illustrative example in thefollowing tables. There are setup parameters and default values whichmay be noted. Table 2 may reveal some display/user interface options.

TABLE 2 Config Option Default Min Max Res Units Description Degree 0  0 1 1 Temperature display temperature 0: ° F. display 1: ° C. Maximum 8545 99 1 F. Highest the occupied cooling setpoint can Occupied Cooling beadjusted. Setpoint stop MaxCoolStPt >= OccCl >= OccHt + 2 DisplayResolution: 1 (F./C.) Minimum 55 40 90 1 F. Lowest the occupied heatingsetpoint can Occupied Heating be adjusted. Setpoint Stop MinHeatStPt <=OccHt <= OccCl − 2 Display Resolution: 1 (F./C.) Unoccupied Heat 55 4090 1 F. Setpoint Standby Heat 67 40 90 1 F. Setpoint Standby Heat 67 4090 1 F. Setpoint Occupied Heat 70 40 90 1 F. Setpoint Occupied Cool 7545 99 1 F. Setpoint Standby Cool 78 45 99 1 F. Setpoint Unoccupied Cool85 45 99 1 F. Setpoint Clock format 0  0  1 1 0: 12-hour clock format 1:24-hour clock format Keypad lockout 0  0  2 1 Keypad lockoutenable/disable through level special keypad sequence. 0: No lockout, 1:Lockout all keys except Temporary Occupied, increase, decrease andinformation**. 2: Lockout all keys except information**. ** Do not allowadjustments on dehumidification high limit setpoint. System Switch 0  03, 7 1 0: Auto 1: Cool 2: Heat 3: Emergency Heat 7: OffTable 3 shows an input/output configuration.

TABLE 3 Config Option Default Min Max Res Units Description Remote space0 0 2 1 0: Local sensor only. temperature sensor 1: Remote sensor only.2: Network Rm Sensor (Sub-base) Space humidity 0 0 3 1 0: No spacehumidity sensor. sensor 1: Local space humidity sensor enabled. 2:Remote space humidity sensor enabled. 3: Network room RH sensor(Sub-base) Discharge air 0 0 1 1 0: No discharge air sensor. sensor 1:Discharge air sensor enabled. Outside air sensor 0 0 2 1 0: No outsideair sensor. 1: Outside air sensor enabled 2: Network OAT sensor(Sub-base) Auxiliary contact 0 0 3 1 0: Time of day contact. operation1: Economizer contact. 2: Dehumidification hot gas bypass contact 3:Simple Dehumidification contacts. Notes: Aux contact not available ifheat pump selected and Sub-base #1. Occupancy Sensor 0 0 2 1 0: NoOccupancy sensor. 1: Use Remote Occupancy sensor. 2: Use NetworkOccupancy sensor (future).Table 4 reveals the fan operation options.

TABLE 4 Config Option Default Min Max Res Units Description Fan Switch 00 1 1 0: On 1: Auto Fan Operation 0 0 1 1 0: Conventional applicationswhere equipment controls fan operation in heat mode. That is, the plenumswitch controls the fan when in heat mode and the Thermostat controlsthe fan when in cool mode. 1: Electric heat applications wherethermostat controls fan operation in heat mode. Extended fan 1 0 1 1 0:No extended fan operation after call for operation in heat ends. heating1: Fan operation extended 90 seconds after call for heat ends. Extendedfan 0 0 1 1 0: No extended fan operation after call for operation incooling ends. cooling 1: Fan operation extended 45 seconds after callfor cool ends.Table 5 shows the control tuning options.

TABLE 5 Config Option Default Min Max Res Units Description Cycler 4 215 1 R Thermostat Cycler Authority Authority (Theta).Table 6 reveals the cooling operation options.

TABLE 6 Config Option Default Min Max Res Units Description CoolingOutput 2 0 4 1 Stages of cooling. stages 0: No cooling. 1: One coolingstage. 2: Two cooling stages. 3: Three cooling stages. 4: Four coolingstages. Cooling system 0 0 1 1 Cph 0: Standard response 3 cph. response1: Fast response 4 cph Cooling TR 4 1 30 1 R Cooling proportional gain(deg F.) Cooling IT 2500 0, 10 5000 1 Sec Cooling integral time(seconds). 0 = disable. Cooling DT 0 0 3000 1 Sec Cooling derivativetime (seconds). 0 = disable. Cooling Action 0 0 1 1 Cooling action.Applies only to proportional outputs. 0 = direct acting. 1 = reverseacting Cooling Lockout 0 0 1 1 0: No OAT lockout 1: cooling locked outif Outdoor air valid and OAT < ClgLockoutSP Cooling Lockout 35 −40 120 1F. SP. DAT Low Limit 45 35 60 1 F. Discharge Air Temperature Low Limit.Minimum cool 3 0 20 1 F./Hr Minimum cooling recovery ramp rate, 0-36°F./hr. recovery ramp rate Min cool OAT 90 −20 100 1 F. Minimum coolingoutdoor air temperature Max cool recovery 6 0 20 1 F./hr Maximum coolingrecovery ramp rate ramp rate Max cool OAT 70 −20 100 1 F. Maximumcooling outdoor air temperatureTable 7 shows the heating operation options.

TABLE 7 Config Option Default Min Max Res Units Description Heatingoutput 2 0 3 1 Stages of heating. stages 0: No heating. 1: One heatingstage. 2: Two heating stages. 3: Three heating stages. (Not available ifconfigured for 4 stages of cooling) Auxiliary heating 0 0 2 1 0: Noauxiliary heating stages 1: one stage of auxiliary heat 2: two stages ofauxiliary heat Heating system 1 0 3 1 0: Standard response 3 cph.response 1: Medium response 6 cph. 2: Fast 9 cph 3: Super fast response20 cph Heating TR 4 1 30 1 R Heating proportional gain (deg F.) HeatingIT 2500 0, 10 5000 1 Sec Heating integral time (seconds). 0 = disable.Heating DT 0 0 3000 1 Sec Heating derivative time (seconds). 0 =disable. Heating Action 1 0 1 1 Heating action. Applies only toproportional outputs. 0 = direct acting. 1 = reverse acting HeatingLockout 0 0 1 1 0: no lockout 1: heat locked out if OAT valid and (OAT >HtgLockoutSP) Heating Lockout 70 −40 120 1 F. SP. DAT High Limit 110 65140 1 F. Discharge Air Temperature High Limit Minimum heat 5 0 20 1F./hr Minimum heating recovery ramp rate recovery ramp rate Min heat OAT0 −20 100 1 F. Minimum heating outdoor air temperature Maximum heat 8 020 1 F./hr Maximum heating recovery ramp rate recovery ramp rate Maxheat OAT 40 −20 100 1 F. Maximum heating ramp rate outdoor airtemperatureTable 8 shows the heat pump options.

TABLE 8 Config Option Default Min Max Res Units Description Heat 0 0 1 10: Conventional Pump Control Control 1: Heat Pump Control Heat 1 0 1 10: energize O/B on Pump call for Heat Reversing 1: energize O/B on Valvecall for CoolingTable 9 reveals the relative humidity control options.

TABLE 9 Config Option Default Min Max Res Units Description RH highlimit 65 10 90 1 % Relative Humidity high limit setpoint. Dehumidifyusing 0 0 1 1 0: None minimum ON time 1: Dehumidification using minimumon time Dehumidify Min 5 5 15 1 min This is the minimum on time used forif On Time the user chose “Dehumidify Minimum On”. Dehumidify using 0 01 1 0: None reset 1: Dehumidification using Room Temperature SetPointreset Dehumidify using 0 0 1 1 0: None reheat 1: Dehumidification usingreheat HumTempReset 2 1 5 1 R Humidity temperature reset The dehumidifyreset must be smaller than the occupied zero energy band (ZEB) orstandby ZEB.Table 10 is a list of energy management options.

TABLE 10 Config Option Default Min Max Res Units Description Demandlimit 3 0 10 1 R Demand limit control set point bump control bumpSequential start 0 0 15 1 Delay in 10 second increments. 0 is no delay.Delays start of equipment after power restored to thermostat. Forexample, setting of 3 is a 30 second delay.   0-0 seconds  1-10 seconds 2-20 seconds . . . 15-150 secondsTable 11 indicates the calibration options.

TABLE 11 Config Option Default Min Max Res Units Description Temperature0 0 7 1 Room Temperature display adjustment display adjustment 0: Nodifference in displayed temperature and actual room temperature. 1:Display adjusts to 1° F. (0.6° C.) higher than actual room temperature.2: Display adjusts to 2° F. (1.1° C.) higher than actual roomtemperature. 3: Display adjusts to 3° F. (1.7° C.) higher than actualroom temperature. 4: Display adjusts to −4° F. (0.6° C.) lower thanactual room temperature. 5: Display adjusts to −3° F. (1.1° C.) lowerthan actual room temperature. 6: Display adjusts to −2° F. (1.7° C.)lower than actual room temperature. 7: Display adjusts to −1 F. lowerthan actual room temperature.Table 12 shows the override and bypass options.

TABLE 12 Config Option Default Min Max Res Units Description Temporary 20 7 1 Hr Override duration in hours. override duration 0: 1 hour 1: 2hours . . . 7: 8 hoursTable 13 shows a time schedule with default time schedule settings. Thetime resolution may be one minute. The limit may be no more than twooccupied or two unoccupied or two standby events per day.

TABLE 13 Day Event Mode Time Sun 0 1 2 3 4 Mon 1 1 Occupied  8:00 AM 2Unoccupied 10:00 PM 3 4 Tue 2 1 Occupied  8:00 AM 2 Unoccupied 10:00 PM3 4 Wed 3 1 Occupied  8:00 AM 2 Unoccupied 10:00 PM 3 4 Thr 4 1 Occupied 8:00 AM 2 Unoccupied 10:00 PM 3 4 Fri 5 1 Occupied  8:00 AM 2Unoccupied 10:00 PM 3 4 Sat 6 1 2 3 4 Hol 7 1 2 3 4

Table 14 shows the daylight savings schedule settings. The default rangemay be from the first Sunday in April to the last Sunday in October.

TABLE 14 Config Option Default Min Max Res Units Description DlsStartDay33 0 74 1 0: None 1, 2, 3, . . . 31, 32: LastDayOfMonth 33: FIRST_SUN34: FIRST_MON . . . 67: FIFTH_SAT . . . 74: LAST_SAT DlsStopDay 68 0 741 0: None 1, 2, 3, . . . 31, 32: LastDayOfMonth 33: FIRST_SUN 34:FIRST_MON . . . 67: FIFTH_SAT . . . 74: LAST_SAT DlsStartMonth 4 0 12 10: None 1: Jan, . . . 12: Dec Default Value: April DlsStopMonth 10 0 121 0: None 1: Jan, . . . 12: Dec Default Value: October

Table 15 relates to holiday schedule settings. This table shows onetypical schedule of ten schedules.

TABLE 15 Config Option Default Min Max Res Units Description Holiday 0 012 1 0: Unprogrammed Schedule 1: January Month 12: December Holiday 0 074 1 0: Unprogrammed Schedule 1, 2, 3, . . . 31, Day 32: LastDayOfMonth33: FIRST_SUN 34: FIRST_MON . . . 67: FIFTH_SAT . . . 74: LAST_SATHoliday 0 0 99 1 days 0: No holiday duration 1: 1 day holiday 99: 99 dayholiday

Table 16 is a default holiday schedule. Configuration tool 12 mayprovide the following default holidays.

TABLE 16 Holiday Month Day Duration New Year's Day 1  1 1 Memorial Day 5Last Monday 1 Independence Day 7  4 1 Labor Day 9 First Monday 1Thanksgiving 11 Fourth Thursday 1 Christmas 12 25 1

Table 17 relates to a real time configuration with real time clocksettings.

TABLE 17 Config Option Default Min Max Res Units Description Clock Year255 0 175, 255 1 Valid range is Jan. 1, 2000 to Dec. 31, 2175 0: 2000 1:2001 2: 2002 . . . 175: 2175 255: Invalid/Not Used Clock Month 0 0 12 10: Unprogrammed 1: January . . . 12: December Clock Day 0 0 31 1 0:Unprogrammed 1: 1 2: 2 31: 31 Clock Minutes 720 0 1439 1 0: Midnight =first minute of the day 720: noon. 1439: 11:59 p.m Clock Seconds 0 0 591 0: 0 = first second of the minute 1: 1 . . . 59: 59 = last second ofthe minute

Configuration tool 12 may calculate a configuration identification as afunction of a selected group of thermostat 11 configuration parameters,using an algorithm. Configuration tool 12 may display the computedthermostat 11 configuration identification. There are configurationparameter dependencies. Here are summarized configuration rulesgoverning limits on parameter data entry and display in the context ofthermostat 11 functional sub-base configured inputs, configured outputsand occupancy mode. There may be a temperature setpoint and modedependency. Configuration tool default time values may be initializedbased on the context of the user selected occupancy mode. Table 18 showsdefault schedule time values. Events 1 and 3 may be either occupied orstandby. Events 2 and 4 may be either standby or unoccupied. It may bethat there should be no more than two occupied or two unoccupied eventsper day.

TABLE 18 Mode Selected Default Time Occupied  8:00 AM Standby 11:30 AMUnoccupied 10:00 PM 

Table 19 reveals the set point range and resolution. Setpointconstraints may include MinHeatStPt<=OccHt<=OccCl−2,MaxCoolStPt>=OccCl>=OccHt+2, UnoccHt<=OccHt<=OccCl−2,UnoccHt<=StdByHt<=StdByCl−2, UnoccCl>=OccCl>=OccHt+2,UnoccCl>=StdByCl>=StdByHt+2.

TABLE 19 Config Option Min Max Res Units Cooling Setpoint 45 99 1 F. 737 1 C. Heating Setpoint 40 90 1 F. 5 32 1 C.

A heat pump configuration screen context rule may be to enable a heatpump configuration if the sub-base type is 1, 2 or 3. A standard controlconfiguration screen context rule may be to enable a standard controlconfiguration if the sub-base type 1, 2, 3 or 4. A dehumidificationconfiguration screen context rule may be to enable if the sub-base typeis 3 or 4 and the relative humidity sensor is configured. A variablerecovery rate configuration screen context rule may be to enable if thesub-base type is 2, 3 or 4 and the outside air temperature (OAT) sensoris enabled. The relative humidity sensor configuration screen contextrule may be to enable if the sub-base type is 3 or 4. The discharge airtemperature (DAT) and OAT sensor configuration screen context rule maybe to enable if the sub-base type 2, 3 or 4.

Sub-base 1 may be a base wall plate configuration. A total of fourrelays may be available with the thermostat and sub-base. An auxiliaryrelay may be configured for an economizer, the time of the day,dehumidification, or an additional stage of heating or cooling. Theselections that may be disabled are the relative humidity Sensor, theDAT sensor, the OAT sensor, the occupancy sensor and the remote roomsensor. Table 20 shows an installer configuration option for sub-base 1.

TABLE 20 Installer Configuration Option Sub-base 1 Heating output 1stages Cooling Output 1 stages Room humidity 0 sensor

Sub-base 2 may be a two heat stage/two cool stage basic configuration. Atotal of six relays may be available with the thermostat and sub-base.The auxiliary relay may be configured for an economizer, time of the day(TOD), dehumidification, or an additional stage of heating or cooling.The selections that may be disabled are the network input options, therelative humidity sensor and the occupancy sensor. Table 21 shows aninstaller configuration option for sub-base 2.

TABLE 21 Installer Configuration Option Sub-base 2 Heating output 2stages Cooling Output 2 stages Room humidity 0 sensor

Sub-base 3 may be a three heat stage/three cool stage configuration.This sub-base may allow for conventional or heat pump operation. A totalof 8 relays may be available with the thermostat and sub-base. Theauxiliary relay may be configured for an economizer, the time of theday, or dehumidification. This sub-base may be configured for a two heatstage/four cool stage configuration by using the third stage of heat foran additional stage of cooling. The selections that may be disabled arethe network input options. Table 22 shows an installer configurationoption for sub-base 3.

TABLE 22 Installer Configuration Option Sub-base 3 Heating output 3stages Cooling Output 3 stages Room humidity 1 sensor

Sub-base 4 may be a modulating configuration. Relative to the modulatingsub-base configuration screen context rules, a total of 4 relays may beavailable with the thermostat and sub-base. The auxiliary relay may beconfigured for an economizer, time of the day, dehumidification or anadditional stage of heating or cooling. The cooling and heating action(direct and reverse) may be shown. Table 23 shows an example installerconfiguration option for the various sub-bases.

TABLE 23 Installer Configuration Sub- Sub- Sub- Sub- Option base 1 base2 base 3 base 4 Heating output stages 1 2 3 0 Cooling Output stages 1 23 0

PDA configuration tool 12 may arrange and store user preferences. Apreference selection for units may include SI (C) and US conventional(F). There may be a preference for alert messages such as anenable/disable alert warning regarding unsupported PDA OS™ versions.User preferences may be stored in a dedicated file. There may be oneuser preference set per PDA platform.

Preferences for regional design parameters may be stored in a defaultthermostat configuration. New configuration files may be instantiatedwith the default thermostat configuration. The user may modify thedefault thermostat configuration. One may lock configuration defaultfiles. The user preferences may support functions for locking andunlocking the default configuration files including the generalthermostat configuration, the weekly schedule and the holiday schedule.

The configuration tool database manager may support 250 namedconfiguration files in a space of 500K bytes of PDA memory. The toolapplication software may use up to 500K bytes of PDA memory.

The following figures effectively show what may be displayed on a PDAwhen configuring or doing settings. FIG. 3 a may be the opening screenof configuration tool 12 of programmable thermostat 11. One mayconfigure offline by selecting a new configuration. Then, in the nextscreen, illustrated in FIG. 3 b, one may enter a description of the newconfiguration under “Description”.

One may connect and configure with an existing arrangement on the PDA.Various versions of firmware and software in thermostat 11 may supportthe processes in the following figures. FIG. 4 a is an opening screenwhere one may click “Select Existing Config”. The next screen in FIG. 4b shows existing configurations on which one may click “Example 2”,which may result in the next screen as illustrated in FIG. 4 c. Here,one may click “Downld”, which may bring a screen as shown in FIG. 4 d.Then one may click “OK” to connect the PDA serial port to the T7350thermostat. On the other hand, one may configure a new arrangement andthen connect in FIGS. 5 a, 5 b and 5 c. One may click a “New Config” onthe opening screen of FIG. 5 a and enter the new configuration name andits description on the next screen in FIG. 5 b. The thermostat may beconfigured clicking the “Next” button to navigate it for entering thenew configuration selections, features and settings. Clicking the“DownLd” button may result in the screen of FIG. 5 c for the opportunityof serially connecting the PDA 12 port to thermostat 11.

FIGS. 6 a through 6 c relate to connecting and modifying the existingconfiguration. On the opening screen of FIG. 6 a, one may click “UploadConfig” and get the connecting screen in FIG. 6 b where one may connectthe PDA to the thermostat by clicking “OK”. In FIG. 6 c, customer XYZconfiguration may be loaded. Using the “Next” button, one may navigateand modify the loaded configuration. After modification of theconfiguration, one may click the “DownLd” button of screen in FIG. 6 cto get the box for connecting PDA 12 to the thermostat 11 fordownloading the modified configuration. FIG. 6 d shows a dialog box forconnecting PDA 12 to the thermostat 11.

FIGS. 7 a and 7 b show screens that may be used for connecting andcalibrating the thermostat. FIGS. 8 a, 8 b and 8 c illustrate thesequence for connecting, reading and saving, that is one may click“Upload Config” on the opening screen and connect in the box that comesup and when ready to save, click the “Save” button in the screen of FIG.8 c. FIGS. 8 d and 8 e relate to monitoring data.

FIGS. 9 a through 9 j illustrate novice configuration and navigation.One, i.e., the user, may click on the “Next” button of the screen of theselected existing configuration, viz., Example 3, in FIG. 9 a tonavigate it. FIG. 9 b shows a selection of sources of inputs for roomtemperature, room relative humidity, discharge air temperature andoutdoor temperature. After clicking the selections, the user may click“Next” and go to another screen for an output selection of “AuxDO” ofthe time of the day, economizer or the dehumid hot gas BP shown in FIG.9 c. A next screen may be the cooling configuration in FIG. 9 d for aselection of the number of stages, cooling response, lockout, and setpoint degrees F. FIG. 9 e shows a similar screen for heatingconfiguration with a selection for stages, auxiliary stages, heatingresponse, lock out and OAT. FIG. 9 f is a screen that relates tofeatures of the fan such as the switch of “On” or “Auto”, operation ofconventional or electric heat, extended operation or not for heat andcool. An events schedule screen in FIG. 9 g provides for themodification of the schedule relative to unoccupied and occupied timesof each day of the week. To insert changes, the user may click on“Modify”, which may bring up the screen shown in FIG. 9 h, where theuser may enter the times of occupancy for the various days of the week.FIG. 9 i shows the screen where one may enter the temperature set pointsfor heating and cooling for the events of a space that is occupied,unoccupied and the standby mode. Also, a temperature override intervalin terms of hours may be entered. The “Summary” screen of FIG. 9 j maybe returned to upon which the user may save the changes to theconfiguration.

FIGS. 10 a through 10 m reveal a sequence for an advanced userconfiguration. FIG. 10 a is a summary screen of the selectedconfiguration. The user may click the “Summary” tab or menu and one getsthe menu across the top of the screen as shown in FIG. 10 b. “Set” maybe clicked for a menu of items that may be set. “Sched” may be clickedas in FIG. 10 c for a menu of scheduling items. One may click “Display”under “Set” in FIG. 10 b and get the screen of FIG. 10 d where certaindisplay options can be selected. Clicking on dehumidification in FIG. 10b, one may get the screen of FIG. 10 e where one may selectdehumidification options. Clicking on “EnergyMgmt” under “Set” mayresult in several choices in FIG. 10 f, such as the demand limit controlbump and the power failure sequence start. Loop tuning under set maybring forth a screen in FIG. 10 g where one may select appropriate setpoints. “Recovery” may be selected under “Sched” on the screen of FIG.10 c where one may select temperatures for starting cooling and heatingbased on outside air temperatures and ramping up and down rates, as inFIG. 10 h. The daylight saving time selected under schedule may resultin the screen as shown in FIG. 10 i where the start and stop of daylightsaving is to start and stop for the year. The “Holiday” selection underschedule may result in the list of holidays in FIG. 10 j or 10 l ofwhich one may want to click on “Modify” to get the screen in FIG. 10 kand thereby select the start time and duration of the selected holiday.The user may click on “Opt” in FIG. 10 c and then click on “User Pref”.Then one may select units, the OS alert message and the lock of defaultsas shown in FIGS. 11 a and 11 b.

FIGS. 12 a through 12 c show file commands. One may click on “Summary”to get the menu which includes “File”. A click may be applied to “New”,“Open”, “Save”, “Save As”, “Beam” or “Delete” relative to aconfiguration. FIGS. 12 b, 12 c, 12 d and 12 e show the resultingscreens, respectively, to start a new configuration, open a currentconfiguration, save a configuration as and delete a configuration.

The time clock may be set with configuration tool 12. However, theconfiguration tool should be connected to thermostat 11 so that thethermostat real time clock may be set. The calendar year, month and daymay also be set. These settings may be effected by using the PDA 12 timeor it may be entered manually. FIG. 13 shows the screen for the setclock mode.

FIG. 14 a shows a start-up screen for a tool on a Palm™ PDA 12. The mainscreen appears in FIG. 14 b and one may upload a program from thermostat11. Then “set up” may be selected in FIG. 14 c and get to a program inFIG. 14 d. One may select a day such as Sunday to schedule. FIG. 14 eshows a schedule of Sunday and the occupied time may be selected, as inFIG. 14 f. One may select the even time or time period for that occupiedtime in the screen of FIG. 14 g and do the set points in the screen ofFIG. 14 h. One may also do the installer set up, for example, relativeto the display in FIG. 14 i. Setup 2 may include selecting the heat andcool stages, for energization selection and sensor location, as shown inFIG. 14 j. Then one may load the program for a particular file, to befor the HVAC system for a particular location, such as a merchant, like“Standard 1”, as indicated in FIG. 14 k. The configuration for Standard1 may be downloaded to the respective thermostat 11, as in FIG. 141.This configuration may also be saved under a file name in FIG. 14 m.

FIGS. 14 n, 14 o and 14 p show screens about the enabling of partialdownloads after the opening screen. Partial downloads may include weeklyschedule, holiday and set points. FIG. 14 q has “Home” added to the Setmenu for returning to the opening screen in FIG. 14 r. The user may beasked to save the current configuration before moving on.

PDA tool 12 may support thermostat field commissioning tasks including atemporary checkout mode (such as eliminating time delays) as well as amanual output mode. FIGS. 14 s-14 z are screens supporting an overrideoption scenario. The screen of FIG. 14 s or 14 t may provide the menu orhome screen, respectively, for selecting an override option. FIG. 14 ushows the connection message. FIGS. 14 v and 14 w reveal overridescreens for “Mod SubBase” and “3H3C SubBase”, respectively. In theoverride screen of FIG. 14 x, the user may tap the manual button.Tapping the screen of FIG. 14 y may let the user exit the manual mode.The screen of FIG. 14 z may warn the user if there is an exit withdelays off or disabled.

Configuration tool 12 may be connected to thermostat 11 to read anonline status report. The status report may include data, but notlimited to, such as the thermostat firmware version, thermostat hardwareversion, sub-base hardware version, run time error messages, spacetemperature, remote temperature set point input, discharge airtemperature, outside air temperature, number of heating stages active,heating capacity output in percent, number of cooling stages active,cooling capacity in terms of percent, remote space relative humidity inpercent, occupancy status (on or off), effective fan setting (on, off orauto), fan status (on or off), mode (heating or cooling), economizerlogic state (on or off), occupancy override status, and run time data.The configuration arrangement and/or the online status report may betransferred (HotSync) to, for instance, a Palm™ or desktop PCapplication or to another PDA 12, via light beam technology or otherways. Thermostat configuration summaries may be saved to a Palm™ memo,which may also be similarly transferred. There may be a password orother security approach to prevent other PDA users from changing thedefault files established by the local control manager.

PDA 12 may be connected to thermostat 11 to make limited changes, suchas one or several configuration parameters, holiday schedules, weeklyschedules, operating mode, temperature settings, and so forth. The PDA12 tool may support thermostat field commissioning tasks including acheck-out mode (eliminating time delays during check-out). The check-outmode may be automatic or manual. Table 24 shows a configuration optionwith related information.

TABLE 24 Config Option Default Min Max Res Units DescriptionDisableDelays 0 0 1 1 0: Not in system Checkout Mode 1: In SystemCheckout Mode (disable delays on relays, sequential start, . . . etc)ManualMode 0 0 2 1 There may be a couple of bits for mode: 0 = Run, 1 =manual, 2 = Factorytest. ManualMode 0 0 2 1 Each relay/AO labeled on thePalm like it is on the Stat. So the Palm would determine if it is a Heatpump or conventional and then display the labels. ManualMode 0 0 2 1Will provide a Manual Mode to turn on/off each output. The user entersand exlts manual mode using the PalmTM OS Configuration Tool. The T7350automatically terminates manual mode if periodic updates are notreceived or the user disconnects the serial cable from the PalmTM OSConfiguration Tool. ManualMode 0 0 2 1 Manual Mode is not a flashed“permanent” state. Manual mode or test- speedup mode is not rememberedthrough a power down or restart. Relay1 0 0 1 1 There will be 8 bits (1byte) for the 8 relays. 0 = off 1 = On Relay2 0 0 1 1 Relay3 0 0 1 1Relay4 0 0 1 1 Relay5 0 0 1 1 Relay6 0 0 1 1 Relay7 0 0 1 1 ModOut1 0 0100 1 % There will be 2 bytes for the modulating outputs: 0-100% each.When thermostat sees mode change to manual, it may set the outputs tothe values specified. ModOut2 0 0 100 1 %

One may monitor thermostat operating data to determine the health of thethermostat. Tables 25 and 26 indicate the various configuration itemsand parameters that may be monitored. Table 25 shows the input data thatmay be monitored.

TABLE 25 Min Max Res Units Description Space Temperature Remotetemperature setpoint input DAT OAT Space RH % Occupancy sensor status(on/off) Fan status (on/off) Occupancy override status

Table 26 shows the output data that may be monitored. Operating modesmay likewise be monitored.

TABLE 26 Min Max Res Units Description # of heating stages activeHeating capacity output % # of cooling stages active Cooling capacityoutput % Economizer logic state (on/off)

Table 27 lists some models and their data that may be monitored.

TABLE 27 Min Max Res Units Description Dehumidification: ReheatDehumidification: SetPoint Reset Dehumidification: Min On Time ExtendedRecovery Mode Operational Mode: Heating/Cooling Effective SetPoint DLCReal Time Operating Date Heating Lockout Mode Cooling Lockout Mode

Thermostat operating data may be monitored. A table 28 may provide datavalues with display dependency rules.

TABLE 28 Display Report Thermostat Data Display Dependency TextDescription Comments version.major A FirmwareVersion: 0.0.19version.minor version.bug version.commVer V ComVersion: 1version.rePgmrVer V ReProgrammerVersion: status3.subBaseType ASubBaseID: T7350D, 3H3C subBase.connected V CommunicatingSubBase: YesstatusAnalog.spaceTemp A RoomTemperature: 75 F statusAnalog.dischTemp Dconfigured DischargeAirTemp: 105 F config.dischAirSensorstatusAnalog.spaceHumidity D configured Room RH: 33%config.humiditySensor statusAnalog.oDTemp D configured OutdoorAir: 25 Fconfig.oDAirSensor statusAnalog.remoteStPtOffset D configuredRemoteSetPtOffset: 2 F config.remoteSetPoint statusAnalog.temporarySetPtD value <> 0 TemporarySetPt: 76 F Display actual temporary setpoint ifDelta value <> 0 status1.totalError N Total error reported by thecontrol loop. status1.bypassTime D value > 0 BypassTime: 180 minstatus1.tuncos N Time until next scheduled change of occupancy state:status1.DaysLeftKeypadHoliday D value > 0 HolidayDaysRemaining: 7status1.currentState A TimeSchedule: OCC Current scheduled occupancystate 0: OCC 1: UNOCC 2: BYPASS 3: STANDBY 7: OCCNUL status1.nextState Nstatus1.occSensor D configured OccSensor: 0 config.occSensor = 1status1.holiday N status2.heatStgsOn A configured HeatingStagesActive: 2D configured AuxHeatingStagesActive: 2 Control = HeatPumpstatus2.coolStgsOn A configured CoolingStagesActive: 1status2.percentCmdHeat D configured HeatingOutput: 57% SubBaseID = Mstatus2.percentCmdCool D configured CoolingOutput: 33% SubBaseID = Mstatus2.outFan N status2.outCool1 N status2.outCool2 N status2.outCool3N status2.outAux A status2.outHeat1 D configured O/BChangeoverOver: ONControl = heatpump config.heatPump status2.outHeat2 N status2.outHeat3 Nstatus2.effMode A EffectiveMode: Cool Effective operating mode: 0:OFF_MODE 1: COOL_MODE 2: HEAT_MODE 3: EMERG_HEAT_MODE 4: REHEAT 5:MANUAL 6: FACTORY_TEST status2.fan A FanStatus: ON status2.auxRelay Dconfigured Economizer: ON NotHeatPmp AND Subbase >1 config.auxOpMode = 1D configured HotGasDehumidification: config.auxOpMode = 2 ON Dconfigured SimpleDehumidification: config.auxOpMode = 3 ON D configuredTimeOffDayContact: ON config.auxOpMode = 0 status2.unused1 Nstatus2.stagesActive N configured status2.noAuxHeat1 Nstatus2.noAuxHeat2 N status2.dehumidActive N configuredDehumidification: ON RH sensor configured status2.DALimit D configuredDishargeAirLimiting: ON config.enableDALoLimit = 1 ORconfig.enableDAHiLimit = 1 status2.unused2 N status3.effOccTuncos Nstatus3.effSetPt_s6 A EffectiveSetPoint: 72 F status3.effOccCurrentStateA EffectiveOccupancy: OCC status3.unused1 N status3.effOccNextState Nstatus3.unused2 N status4.terminalLoad V Display Key: A - Always displayD - Display based on context Dependency N - Never displayed V - Verbosemode only

One may backup thermostat configuration files from PDA 12 to a PC. ThesePDA configuration files may be restored in the event of battery failureor PDA demise or loss. If the latter occurs, one may go to a store andpurchase another PDA and upload the files from the PC, and continueabout the business with the new PDA.

A PC archive of thermostat configuration information may have severalbenefits. The PC archive database may support multiple PDA users.Individual thermostat configuration files may be organized in groups bycustomer building or project name. PDA users may from such databaseselect individual configurations and incrementally install them on aspecific PDA using the PC hot sync function. The function may behardwired or be of an IR or other wireless method. Other connectivefunctions may be implemented. There may be last session information. Inother words, the PDA or PC user may be returned to the last editedconfiguration file and last used configuration screen. Also, a list ofthe last five or so configuration files opened by the user may bepresented upon going into the configuration program. There may also bevarious warnings about the adequacy of the PDA hardware and software.

The PDA user may be able to field calibrate analog outputs. For highaccuracy on the analog outputs or inputs, the user may modify gain andoffset constraints. For instance, the user may field calibrate thehumidity sensor. The user may be able to add an offset to the sensorreading. Various abbreviated titles, terms and acronyms may be connectedby PDA 12 with a button toggle to obtain the full title or meaning. Forinstance, one may toggle on “LeadTimeInfo” to get “Lead Time Table ofInformation.”

PDA 12 may not only upload a configuration from thermostat 11, but itmay be able to upload a contractor's name, logo and telephone number.This information may be presented on the screen of PDA 12. Also, it maylikewise be displayable on thermostat 11. Such information may be usefulin case there is a thermostat problem, regular preventive maintenance orroutine check scheduled, filter change needed, a seasonal configurationchange, or other items in which contacting a contractor could behelpful.

FIG. 15 is a flow diagram of an entry of a contractor's phone number andlogo graphic (and possibly additional information) on a PC at block 16.The format of the logo graphic may be checked at junction 17. If theformat is not proper, then it may be converted at block 18. If or whenthe format is proper, then it may be checked for size at junction 19. Ifthe logo is not the correct size, then it is not resized at block 20. Ifand when the logo is of acceptable size, then the contractor informationmay be stored in the PC. At block 21, the contractor information may betransferred as data from the PC to a PDA or portable memory media (e.g.,smart media, compact flash or a memory stick). At block or step 22, thecontractor information data may be transferred to thermostat 11EEPROM/FLASH 23 via PDA 12 using an easy wire, IR or RF connection, orvia a portable memory.

The electronic thermostat assembly may consist of two pieces, the coverassembly 30 and sub-base 14. The cover assembly may include, but is notlimited to, the MMI and a display 38 for 7-day programming. Assembly 30and display 38 are shown in FIGS. 17 b and 17 a, respectively. Thesub-base(s) include the equipment control connections. The sub-base ismounted on the wall and the thermostat cover assembly is mounted on thesub-base. Different sub-bases will be used for different applicationsincluding; up to 3 heating stages/3 cooling stages or 2 heating stages/4cooling stages, modulating outputs, and dehumidification high limitcontrol. Each sub-base is compatible with the common cover assembly.

There may be a disable delay/sequential start option. This may allowfaster testing in the field by disabling the minimum on/off time delaysfor relay outputs and the sequential start delay. The rate at which thecontrol algorithm runs (once every 10 seconds) determines the rate atwhich stages cycle on and off. Other test options may include thefollowing.

The installer may enter the disable delay option by pressing a specialcombination of keys and selecting “in-test” and then pressing the “run”key. The installer may exit the disable delay option by pressing aspecial combination of keys and selecting “no-test” and then pressingthe run key.

There may be a capability to field flash thermostat 11 from the serialport. This may allow the user to upgrade the firmware in the field.Initially, a lap-top PC 24, running a special program may be used toconnect to the thermostat serial port. Later, a program may be developedto do this through the Palm™ OS configuration tool. Scheduleprogramming, installer configuration options, set points, system switch,fan switch, and keypad lockout may all be field adjustable through thethermostat keypad/LCD or a Palm™ OS configuration tool. Some parametersmay be configured and monitored only through the Palm™ OS configurationtool. Others can be configured and monitored from both the keypad/LCDand Palm™ OS configuration tool 12.

FIG. 16 is a thermostat system level diagram with major components and asystem communications overview. Thermostat 11 may interface with remoteair management system or HVAC equipment controls 26, external sensorsand switches 25, and a remote wall module 27. Signals, includingcommands to equipment, between thermostat 11 and air management or HVACcontrols 26 may be via connection 33. External sensors and switches 25may include discharge air temperature, outdoor air temperature, humidityand occupancy sensor. Information from sensors and switches 25 may beconveyed along connection 29 to thermostat 11. Remote wall module 27 mayinclude a temperature sensor, an override switch with an LED and awarmer/cooler (set point offset) knob, with related information beingconveyed between module 27 and thermostat 11 along connection 31.

Thermostat 11 may have a serial communications set-up or interfacemodule 28 to allow inboard and outboard information to go betweenthermostat 11 and set-up 28 along a connection 32. Communicationsbetween set-up or module 28 and an external device 56, such as aninstaller configuration tool 12 and a communicating sub-base 14, may bevia a connection 34. Firmware to thermostat 11 may be downloaded form anappropriate device 36 via a JTAG interface connection 37.

Thermostat 11 may be configured using an “Installer Setup” through thethermostat keys on cover assembly 30 for basic setup functions. Moreadvanced features may be available through installer configuration tool12. Installer configuration tool 12 may be compatible with a Palm™ OShandheld computer.

There may be a thermostat 11 output modulation control. This approachmay solve problems associated with control issues by sending analogheating and cooling signals to be implemented by controls of an airmanagement system or roof top unit 40 of FIG. 21. System or unit 40 mayhave a duct 39 for taking in outside air (OA), a duct 41 for taking inreturn air (RA) of a space, and a duct 42 for discharging air (DA). Unit40 includes a cooling unit 43 and a heating unit 44. Severalenhancements and options may exist in the algorithm and thermostatconfiguration to assist and lead to control of water valves andoversized heating coils and loads. There may be various approaches forimplementing analog output and modulation in a thermostat. One may useconfiguration codes in the sub-base combined with a configuration tooland interchangeable sub-bases.

The present electronic thermostat system may consist of two components,thermostat 11 and the sub-base 14. The thermostat may include a humaninterface and display for user programming, the microprocessor, fourrelays, a space sensor and a power supply. The sub-base may includeequipment control connections, additional relays, optional analogoutput, and some power supply components. The sub-base may be mounted onthe wall and the thermostat may be mounted on the sub-base. Differentsub-base types may be used for different applications including up tothree heat/three cool or two heat/four cool, modulating outputs,dehumidification high limit control, and communications with a buildingautomation system. All sub-base types may be compatible with thethermostat.

A Palm™ PDA may be connected to the thermostat and be used to configureor program the thermostat. The communications port may be used by thefactory to test the hardware features of the device. An optional remotewall module may be attached to the device to sense space temperature,control the set point, initiate a schedule override timer, and displaythe status of the override timer.

Thermostat 11 of FIG. 1 may contain a software component in thethermostat that allows automatic configuration of the output actuationtype (modulation and discrete) identified by the sub-base with presetconfiguration resistors. Additional configuration information may beprovided in the Palm™ configuration tool that allows setting of theparameters related to the modulating outputs. The following tablereveals the various options for the sub-bases.

TABLE 29 Installer Configuration Sub- Sub- Sub- Sub- Option base 1 base2 base 3 base 4 Heating output stages 1 2 3 0 Cooling Output stages 1 23 0 Heating Throttling Range ® 3 4 7 5 Cooling Throttling Range ® 3 4 75

The next table relates to modulating system valve control.

TABLE 30 Cooling Valve Applies to the modulating Cooling valve 0 =direct acting. 1 = reverse acting. Heating Valve Applies to themodulating Heating valve 0 = direct acting. 1 = reverse acting.

The hardware component of the output actuation may be implemented thoughan analog output set. The microprocessor may output the signal as a dutycycle signal that is driven into a digital to analog conversion circuit.

This invention may solve the problems associated with control issues byimplementing a true analog heating and cooling signal to be implementedby the roof top 40 control system. Several enhancements and optionsexist in the algorithm and thermostat configuration to assist and leadto control of water valve control and oversized heating coils and loads.Under staging conditions, traditional control algorithm techniques maybe used to control the on/off control to the heating coils, coolingcoils and fan. When used in a modulating configuration, special analogdriver circuits may allow the output from the thermostat to provide 4 to20 milliamps and 2 to 10 volts for direct interfacing for the control ofmodulated components. These control parameters are popular ranges formany modulated dampers and valves used in air management systems, suchas HVACs.

The thermostat may contain a software component that allows automaticconfiguration of the output actuation type (modulation and discrete)identified by the sub-base with preset configuration resistors. Thehardware component of the output actuation may be implemented through ananalog interface set from the thermostat. Analog control and interfaceto the modulation may be controlled through software algorithm PID andstaging information. If additional heating is desired after a stage isadded at low load, additional supply is available through increasing ofthe analog heating signal. Applications of this modulating thermostatmay be used for boiler firing rate controls and other energy supply orcooling type equipment. Through the use of programmable memory,additional algorithms can be developed to apply to a wide range andvariety of control applications besides air management system control.

The present thermostat may provide modulated/analog control of an airmanagement system and discrete/digital control of the same or anotherair management system. This thermostat may provide modulating control ofa single stage of heating and/or cooling. On the other hand, thisthermostat may provide modulating control of multiple stages of heatingand cooling. Using a modulating signal to control each cooling orheating stage may result in maintaining the outputs of the controlledstages at efficient levels. If more output is needed from that stage,the thermostat may, with a modulating output, call on another stage andcontrol it for more heating or cooling, so as to maintain the betterefficiency of the first stage by not increasing the modulating output tothe first stage to increase its output. Also, modulated control mayresult in the next stage's approaching an efficient level of output.This approach may continue for more or less output as needed from therespective stages. The thermostat may provide analog or digital signalsfor controlling single or multiple cooling or heating stages. Thethermostat may have any combination or all of these features.

FIG. 17 is a block diagram of a modulating commercial thermostat system.The system is composed of several major components including aHoneywell™ T7350 thermostat 11, a configuration tool (PDA) 12, andexternal mechanical equipment 57. Thermostat 11 may be composed ofseveral major sections including a cover assembly 30, modulatingsub-base 14 and external sensors. External sensors may include dischargeair sensors 64, outside air sensors 65, a humidity sensor 66, and aspace temperature sensor 67. These sensors may be connected to ananalog-to-digital converter (ADC) 59. Within a cover assembly 30, amicroprocessor 61 may contain the software instructions that control theinterface between the control algorithm and the ADC and digitalinput/output (I/O) blocks 59 and 58, respectively. Microprocessor 61 maybe a microcontroller having a schedule and an algorithm, and a flashmemory. A JTAG connection 37 to microprocessor 61 may allow upgradeablefield programming and real time emulation of operation. A real-timeclock 62 may be connected to processor 61. Sub-base 14 configurationresistor 63 may be read on power-up and provide an indication of aunique resistor value that indicates the presence of a modulatingsub-base.

ADC block 59 may convert the incoming analog resistance values intodigital values that can be read by microprocessor 61. The analogresistors values to ADC 59 may come from discharge air sensors 64,outside air sensors 65, humidity sensor 66, space temperature sensor 67,motion sensor 68, and other sensors 69. Another analog input to ADC 59may be from sub-base configuration resistor 63. A modulation signal maybe derived from a pulse width modulated (PWM) signal conversion circuitwhich converts the time-multiplexed duty cycled signal from thealgorithm of processor 61 into a 4-20 milliampere (mA) modulatingsignal. The 4-20 mA signals may be fed, via the modulating coolinginterface 72 and modulating heating interface 73, to HVAC mechanicalequipment 57 and may be used to control space temperature with analogcontrol dampers among other HVAC mechanical equipment 57, as needed. Adigital I/O 58 may be connected to microprocessor 61. A motion sensor 68and other external sensors 69 may provide signals to processor 61 viadigital I/O 58. Processor 61 may provide signals to cooling relay 74,heating relay 75, fan relay 76 and auxiliary relay 77. The outputs ofthese relays may be connected to HVAC mechanical equipment 57.

Since modulating control of both heating and cooling valves may be undermicroprocessor 61 control via modulating cooling and heating interfaces72 and 73, respectively, and since thermostat 11 may be capable ofhumidity control, the thermostat can in general control or limithumidity effectively through the use of modulating the cooling asnecessary to reduce the humidity of the outside air that typicallyaccounts for most of the humidity load in a commercial building.Different strategies may be used to do dehumidification controlincluding the use of both heating and cooling relays and heating andcooling modulating valves in different ratios. Modulation of dampers tocontrol the volume of air per unit of time through the cooling mechanismmay also be used for dehumidification control.

FIG. 18 is a block diagram of the networked modulating thermostat.Components associated with thermostat 11 may include the systemsequencing control 78, which may be a Lonworks™ communicating node thatallows network information to be shared on a network communications bus84 in the form of “network variables”. Standard network variables mayexist for standard representations of temperature, humidity, and digitalon/off and analog values. Sequencer 78 may have a local sensors 79connection. The availability of modulating controls may allow for amaster sequencing control 78 node to make staging and modulatingdecisions for the whole system based on local sensors. Also, localsensor information may be shared on a one-to-one, or one-to-many basisusing a Lonworks™ process called “binding”. It may allow, for instance,the outside air temperature and outside humidity signals to be sharedacross multiple controllers, including information for temperature andhumidity control for individual nodes 82 and 83. Controller 192 may beassociated with node 82. Controller 192 may have a thermostat 11 and asub-base 14 which are set up for two stage cooling and two stageheating. Mechanical equipment 57 may be driven with digital-like,discrete, non-modulated signals from controller 192. Sources 194, 195and 196 connected to thermostat 11 may provide temperature, humidity andoutside parameter information, respectively, to controller 192. Othercontrollers on bus 84 may likewise have such sources connected to them.Also, a controller 193 may be associated with node 83. Controller 193may have a thermostat 11 and a sub-base 14 which are set up formodulated one stage cooling and heating. Mechanical equipment 57 may bedriven with analog, modulated signals from controller 193. Thermostat 11of controllers 192 and 193 may be the same thermostat or differentthermostats. If these controllers have the same thermostat, thatthermostat may have the capability of controlling both non-modulated airmanagement systems and modulated air management systems.

In FIG. 18, there may be numerous other nodes having additionalcontrollers (though not explicitly shown) associated with them,respectively. The controllers may output non-modulated or modulatedcontrol signals to their respective mechanical equipment which mayconsist of HVACs, respectively, having valves and/or dampers controlledby signal outputs from their corresponding controllers. Often, the airmanagement systems, such as HVACs, that are recipients of thenon-modulated control signals, are multiple stage cooling and heatingsystems. And often, the air management systems, such as HVACs, that arerecipients of the modulated control signals, are single unit cooling andheating systems. However, in lieu of the latter single unit systems,there may be modulated multiple stage cooling and heating systems. Bothmodulated and non-modulated systems may also have humidity control.

Sequencing information may be collected from sensors 79 on node 81 ornetwork binding sensors to allow for sequential staging and algorithmenhancements. Local and non-local sensors may be those for measuringtemperature and humidity, and other parameters. The sensors may besituated in various locations such as outside, the controlled space andin or proximate to the air management equipment. Since the individualnodes may command analog and digital values from both the local node andthe system node, the system node can command individual node analog anddigital values as required in temperature (and sometimes humidity andother parameter) control systems, such as HVACs.

System sequence control 78 may be a controller configured as a sequencerwith controllers 192, 193 and others added and connected to the networkcommunications bus 84. Controllers 192, 193 and the like may act asindividual controllers which periodically send status messages tosequencer 78. Also, sequencer 78 may periodically send information,instructions and commands to controllers 192, 193 and other likecontrollers, if any. Such information, instructions or commands mayaffect the respective controller's control of mechanical equipment 57 ofan HVAC or other air management equipment.

Sequencer 78 may also control a multi-stage heating and cooling systemvia thermostat(s). That is, there may be modulated control of each stageof heating and cooling. The percentage a stage's maximum output may besomewhat less than 100 percent. That percentage may be determined, forexample, by an effective operating efficiency singlely or in combinationwith one or more other stages. Other bases may be used for determinedthe percentage of maximum operation of a stage. The percentages may bedifferent among the stages and dependent upon parameters such astemperatures, humidity and so forth. Sequence control may also be ofnon-modulated stages or of a mix of modulated and non-modulated stages.The sequence may be utilized for air management systems having humiditycontrol. A user interface 197, similar to interface 30, having akeyboard and a display, may be connected to sequencer 78 forprogramming, configuring and testing the sequencer and associatedcontrollers on communications bus 84. A personal digital assistant(e.g., PDA 12) may be connected to user interface 197 or directly tosequencer 78 for programming, configuring and testing the sequencer andassociated controllers on communications bus 84. The connection of thePDA to interface 197 or sequencer 78 may be via a wire or wirelessmedium (e.g., RF, infrared or optical fiber). Each thermostat 11associated with bus 84 may likewise have a user interface 30 and PDA 12as disclosed herein.

FIG. 19 is a flow diagram of the modulating sub-base sequence. An inputmay enter the sequence at decision 85 which asks whether the power iswithin acceptable limits. If not, a power shut-down may be initiatedalong with the saving of the schedule and configuration, as indicated inblock 86. If the power is within acceptable limits, then theanalog/digital (A/D) registers may be initialized and the analog outputscommanded to 4 mA, according to block 87. The output of block 87 may goto block 88 and cause the sub-base configuration resistor ID to be read.The next question of symbol 89 may be whether the modulating resistoridentification (ID) is valid or not. If not, a signal may be sent backto the beginning of block 88 and the process may repeat itself with thesame question of validation of the modulating resistor ID. If theresistor ID is valid, then a signal may be sent from decision diamond 89to block 91 for the temperature and humidity sensors to be read. Afterthese readings, control algorithm action of block 92 may occur. Themeasured value temperature minus a temperature set point may equal theerror, and the humidity error may be a function of humidity value andthe humidity high limit. After the action of block 92, an output may goto symbol 93 to ask whether an analog modulating sub-base is present. Ifnot, then a digital output may be a function of measured temperatureerror, measured humidity error, and configuration type, as in block 94.If so, then a modulating output may be a function of measuredtemperature error, measured humidity error and configuration type, as inblock 95.

FIGS. 20 a and 20 b show an illustrative example of a display 38 and akeypad 45 user interface 30. Keypad 45 may control HVAC equipment oftendescribed as a conventional roof top unit (RTU) 40 with gas or electricheat and direct expansion (DX) cooling. There may be 0-3 stages of heat,and up to 6 stages of heating and cooling combined. There may be 0-4stages of compressor, and up to 6 stages of heating and coolingcombined. There may be a single speed fan. An auxiliary relay may beused to enable economizer dampers, TOD or dehumidification. A heat pumproof top unit 40 may have gas or electric auxiliary heat. There may be0-2 stages of auxiliary heat, 0-3 stages of compressor, a heating orcooling changeover valve, and be configurable for ON for heat or ON forcool. It may have a single speed fan. Also, an auxiliary relay may beused to enable economizer dampers, TOD (time of day) ordehumidification.

A modulating roof top unit may have a hot water valve or modulating gasheat and/or chilled water valve. FIG. 21 shows a typical roof top unit40. Roof top unit may have cooling equipment 43 and heating equipment44. It may also have a fan 46, a DAT 47 and an OAT 48. There may bedampers 49 and 51 to regulate the flow of the outside air and return airto RTU 40. Dampers 49 and 51 may have a common mechanical connection 52which coordinates their movements relative to each other. A controlpanel 50 for RTU 40 may be connected to cooling equipment 43, heatingequipment 44, fan 46, dampers 49 and 51, and a heat pump cutout valve53. Control panel may receive control signals from and send signals tothermostat 11. A DAT sensor 47, an OAT sensor 48, an occupancy sensor 54and a remote sensor 55 may be connected to thermostat 11.

RTU 40 may have a heat enable, cool enable, or 0-2 stages of heat orcompressor. The modulating outputs may be always active. They may bealways being driven 0-100 percent. When the number of stages is zero,the relay outputs may be used to enable heating or cooling outputs. Thismeans the relay may turn on when the modulating output is nonzero andturn off when the output is zero. Staged action may be used in additionto the modulating outputs. The number of stages may be set to 1 or 2, ormore if desired. In this particular case, the relay output(s) may beused for up to 2 stages of heating or cooling. Note that the user mightnot have both two stages of cooling and two stages of heating. Inanother example, the user may have modulated heat, a heat pump enablerelay and one stage of cooling. Or the user may have modulated heat, aheat pump enable relay, and two stages of cooling. The cooling analogoutput may be direct or reverse acting. The heating analog output may bedirect or reverse acting. The may be a single speed fan. Although amultiple speed fan may be used. There may an auxiliary relay used toenable economizer dampers, TOD or dehumidification.

The hardware of thermostat 11 may have the following configuration,which includes an internal room temperature sensor, an LCD display 38with back-lighting, a keypad 45, a system and fan switching capabilitythrough the keypad, as indicated in FIGS. 20 a and 20 b. Also, there maybe a serial communications link from thermostat 11 to configuration tool12 (Palm™ OS) and a network communicating sub-base. There may be fouronboard relays with one for heat, one for cooling, one for a fan, andone auxiliary relay.

Recognition of the sub-base I/O (input/output) may be through thehardware. The thermostat cover assembly may indicate the sub-base I/Oconfiguration by a resistor located on the sub-base. Each I/Oconfiguration may have a unique resistor value. One sub-baseconfiguration may have modulating outputs. A total of four relays may beavailable with a thermostat cover assembly and the sub-base. Theauxiliary relay may be configured for an economizer, TOD,dehumidification or an additional stage of heating or cooling. There maybe a modulating heating output and a modulating cooling output. Alsoincluded may be a humidity sensor mounted in the sub-base, a remote roomsensor, a remote room humidity sensor, a remote discharge airtemperature sensor, a remote outdoor air temperature sensor, and remoteoccupancy input (digital input). There may be access to the serialcommunications port on the thermostat. The modulating sub-base may ormay not support heat pumps.

An open, short, or out-of-range on the internal or remote room sensorinput(s) to the thermostat may cause the outputs to be turned off. Thefault detection might be just done on the sensor being used. That is, ifthe internal sensor is being used, faults on the remote sensor areignored. The system may provide proportional plus integral plusderivative temperature control.

There may be testability capabilities. The thermostat may cooperate withfactory testers such as in-circuit and functional tests to verify itsfunctionality. The industry standard JTAG port will be available for thefactory tester to program the flash memory and test the device. BoundaryScan, formally known as IEEE/ANSI 1149.1_(—)1190 is a standard whichfacilitates testing, device programming and debugging at thesemiconductor, board and system levels. The standard came about as aresult of the efforts of a Joint Test Action Group (JTAG) formed byseveral North American and European companies. IEEE Std 1149.1 wasoriginally developed as an on-chip test infrastructure capable ofextending the lifetime of available automatic test equipment (ATE). Thismethodology of incorporating design-for-test allows complete control andaccess to the boundary pins of a device without the need for abed-of-nails or other test equipment. The OS label applied to thecontrol represents the features of the control. This product may bedesigned such that 100 percent of the inputs and outputs can be testedin the factory.

One may interface to a Palm™ OS tool to do installer configurations, setparameters, set schedules and tests, including factory-like testing, anddiagnostics. The Palm™ OS configuration tool has several basic functionsinstaller configuration (defines the equipment attached to thethermostat); parameter modification (gains, set points, and the like),schedule changes, and testing and diagnostics.

Keypad 45 and LCD display 38 user interface 30 may be in the flashmemory file (accessed through document management software). Thermostat11 may have the LCD segments depicted in FIGS. 20 a and 20 b. FIG. 20 ashows the available LCD elements in display 38. There are elements fordisplaying time, temperature, days of the week, humidity, occupiedstatus, far status, heat and cool status, setting for schedules andtimes, and so forth. Further, display 38 may be a dot-matrix system withshading of the respective pixels. Display 38 may be a black and whitedisplay with a gray scale system, or a color display which is capable ofdisplaying graphics, pictures and symbols, including company orcontractor logos. Display 38 may be capable of displaying video-like ortelevision-type pictures. Interface 30 may have a speaker for providingsound associated with video information on display 38. Also, amicrophone may be attached to interface 30 for voice instructions orother audio purposes.

FIG. 20 b shows user interface 30 with display 38 and keyboard 45.Button or keys 96 and 97 may be used for entering up and down settings,respectively. Key 98 may be used to obtain information. Keypad orkeyboard 45 may have a settings group 99, set group 101, override group102 and a program group 103 of keys. Buttons or keys 104 and 105 may befor the heat and cool temperature set points for occupied periods. Keys106 and 107 may be for heat and cool temperature set points forunoccupied periods. The day and time of the clock may be set with keys108 and 109, respectively. Keys 110 and 111 of override group 102 may beused for temporary occupied and holiday schedule selection,respectively. Alternatively, key 111 may be for “Temporary Not Occupied”override, as indicated in Table 31. One may program schedules ofoccupied and unoccupied times for various days in key group 103. Key 112may be used to select the day to be scheduled, key 113 may be used forselecting the occupied times and key 114 for selecting the not occupiedtimes for the selected day. Key 115 may be used to clear the setschedule of that day. Key 116 may be used to copy a schedule of one dayinto another. Other keys of interface 30, include a system key 117 forselecting a cooling or heating system, and a key 118 for putting the fan“on” or on “auto”. Key 119 may be used to run the system. Table 31provides some description of the various keys on keyboard 45.

TABLE 31 Reference Number Grouping Button Definition 96 Information DownArrow Used for lowering setpoints, days, and times. When setting timesor temperatures, holding this key down results in continuouslydecreasing the time. 98 Information

Used to obtain information (and setting humidity “high-limit” value) 97Information Up Arrow Used for raising setpoints, days, and times. Whensetting times or temperatures, holding this key down results incontinuously increasing the time. 104 Temperature Occupied Heat SetOccupied Heat setpoint 105 Temperature Occupied Cool Set Occupied Coolsetpoint 106 Temperature Not Occupied Heat Set Not Occupied Heatsetpoint 107 Temperature Not Occupied Cool Set Not Occupied Coolsetpoint 108 Set Day Set day of week, Tapping this key when the ‘SetValue’ segment is on will also increase the current day (same effect asup arrow key) 109 Set Time Set time. Tapping this key when the “SetValue” segment is on will also increase the time in one hour increments110 Override Temporary Occupied Temporary occupied setting for length oftime defined by installer. 111 Override Temporary Not Set Not Occupiedlength. User can select length of days Occupied (“0”–“99”), or “—” forcontinuous override 112 Schedule Day Selects day schedule to modify 113Schedule Occupied Selects occupied event start times for specified day.Repeatedly pressing this key toggles between two occupied events. 114Schedule Not Occupied Selects not occupied event start times forspecified day. Repeatedly pressing this key toggles between two notoccupied events. 115 Schedule Clear Start Time Clears start time forspecified period and day 116 Schedule Copy Copies schedule from one dayto another. 117 System Selects System Mode. Toggles between Em Heat,Heat, Off, Cool, and Auto modes. 118 Fan Selects mode of fan operation.Toggles between On and Auto. 119 Run Schedule Resumes running schedule(cancels any Temporary Occupied action, Temporary Not Occupied, orTemporary setpoint change.)In system checkout there may be disable delay, test and monitoring fromPalm™ configuration tool 11. One may be able to access a manual modefrom the Palm™ OS configuration tool. This may allow the user tomanually turn on and off or modulate each output to verify wiring.

The electronic thermostat system may consist of two pieces, thermostat11 and sub-base 14. Thermostat 11 may include a human interface 30 anddisplay 38 for user programming, a microprocessor 61, four relays 74,75, 76, 77, a space sensor 67, and a power supply. Sub-base 14 mayinclude the equipment control connections, additional relays, optionalanalog output, and some power supply components. Sub-base 14 is mountedon the wall and thermostat 11 may be mounted on sub-base 14. Differentsub-base 14 types may be used for different applications including up tothree heat/three cool or two heat/four cool, modulating outputs,dehumidification high limit control, and communications with a buildingautomation system. All sub-base 14 types may be compatible withthermostat 11.

A Palm™ PDA 12 may be connected to thermostat 11 and used to configureor program thermostat 11. Future sub-base 14 types may have thecapability of communications to a building automation system via a netconnection. The communications port may be used by the factory or a PDAto test the hardware features of the device.

An optional remote wall module may be attached to the device to sensespace temperature, control the set point, initiate a schedule overridetimer, and display the status of the override timer. Optional remotedischarge, outdoor air, humidity, and occupancy sensors may be attachedto thermostat 11 via sub-base 14.

In the factory, thermostat 11 may be connected to a programming devicethat programs the flash memory via the industry standard JTAG port. Thisport may also by used to down load revised software in the field.

There may be control algorithms in thermostat 11. Thermostat 11 may beused to control the temperature and humidity in the controlled spaceusing heating and cooling equipment. The equipment may be conventionalwith up to three stages of heating and four stages of cooling, or it maybe heat pump with up to two compressor stages and two stages ofauxiliary heat. In addition economizer options and analog controloptions are available with some sub-bases. The control algorithm may becustomized for various applications using keyboard and display or anexternal personal digital assistant (e.g., PDA 12).

In the factory test phase, the device may cooperate with the factorytester to test the hardware inputs, outputs, keyboard 45, display 38,and associated equipment. The hardware of thermostat 11 may includecertain significant components. Thermostat 11 may use a TexasInstruments Inc. MSP 430 family microprocessor. Processor 61 may containon chip flash program memory, flash information memory, RAM,microprocessor oscillator, real time clock oscillator (externalcrystal), timers for real time clock, timers for operating system andpulse width modulation (analog output), digital IO 58 ports forrelays/inputs/keyboard scanning, 12 bit analog-to-digital converter(ADC) 59 with an input multiplexer, and an LCD display 38 driver.

The microprocessor 61 port pins may be connected to: keyboard 45 rows(inputs) and columns (outputs); an LCD display 38; eight analog inputcircuits (one on thermostat 11 and up to seven connected via sub-base14); one digital input for remote wall module bypass button—connectedvia sub-base 14; one digital input for occupancy sensor—connected viasub-base 14; transistorized relay drivers (four on thermostat 11 and upto four on sub-base 14); a low pass filter to convert pulse widthmodulation into analog output voltage (up to two on sub-base 14); onedigital output for bypass LED on remote wall module—connected viasub-base 14; one digital output to put the power supply into relay powersaving mode; a serial input, output, and handshake input used toconnected to the personal digital assistant 12, sub-base 14communications system, factory tester, or tcomm (a specialty developmenttool); a 32,768 KHz crystal; three volt power derived from a highervoltage power supply (the three volt supply may use a super-capacitor tokeep the circuit alive for 48 hours or more after mains power failure);an on chip low voltage detect circuit which may be connected to themains side of the higher voltage power supply (a detection of lowvoltage may cause microprocessor 61 to enter a low power mode.

The context diagram of FIG. 22 illustrates the various processes inthermostat 11. There may be two kinds of tasks: 1) interrupt driven; and2) operating system driven. The interrupt driven tasks may run when ahardware interrupt calls them. Interrupts do not interrupt interrupts.The operating system tasks may run periodically when an operating system121 calls them. When no tasks are being performed, operating system 121may run in an endless loop. The tasks may communicate with one anotherthrough shared RAM variables. The memory in this illustration may beregarded as RAM, unless otherwise specified. The code may be written inthe C language except that some critical routines or utilities may bewritten in assembler.

Operating system 121 may have an outgoing hardware connection 122 tohardware initialization. One may note a key of symbols for FIG. 22. Adouble line block may represent a main( ) system such as operatingsystem 121. A single solid line block may represent a periodic task(time), a dot-and-dash line block may represent an interrupt task, twohorizontal parallel line symbol may represent a memory, a single linewith an arrow or arrows at least one end may represent an internal datapath and a double line with an arrow at least one end may represent ahardware connection. There may be a two-way internal data pathconnection 123 from system 121 to opsys flags memory 124. From a low rawfilter voltage detector may be an inward hardware connection 125 and alow mains detect interrupt task 126. Task 126 may have an internal pathconnection 127 to opsys flags memory 124. A system clock tick interrupttask 128 may have an output to opsys flags memory 124 via internal datapath 129. A RealTimeClk and Vcc fail/recover interrupt task 131 may havean incoming hardware connection 132 from a low raw filter voltagedetector and Vcc supervisor. Interrupt task 131 may have a two-wayinternal data path connection 133 with opsys flags 124. From interrupttask 131 may be an internal data path connection 134 to RealTimeClockmemory 135, which may be connected to a clock (periodic task) 136 via atwo-way data path 137. Clock 136 may be connected to a central sharememory 130 via a two-way data path 138. Calculate Occ and SetPointperiodic task 254 may be connected to share memory 130 via two-way path267. Share memory 130 may be connected to communications periodic taskblock 140 via a two-way path 139.

Communications task 140 may be connected to realTimeClock 135 via atwo-way data path 141. Output from communications task 140 may go to asecond buffer memory 142 via a one-way data path 143. The output fromsend buffer 142 may go to send character interrupt task 144 via atwo-way data path 145. Task 144 may have an incoming handshake hardwareconnection 146 so as to indicate when character data may be transmittedout via a TX hardware connection 147. Character information may bereceived via RX hardware connection 148 to receive character interrupttask 150. This information may go to a receive buffer memory 151 via aone-way data path 149. The information may then go to communicationsperiodic task block 140 via a one-way data path 152. From communicationstask 140, the received information may go to share memory 130 via datapath 139.

ID interface periodic task 153 may receive digital inputs via a hardwareconnection 154. An output from IO interface 153 may go to share memory130 via a one-way data path 155. An output from share 130 may go to mapoutputs periodic task block 156 via a data path 157. Map outputs task156 may output on a hardware connection 158 PWM outputs and relayoutputs. Also, an output from map outputs task 156 may go to a digitalIO memory 160 via a data path 159. Such output may go to IO interfacetask 153 via a two-way data path 161. IO interface 153 may provide relayoutputs and remote LED signals on an outgoing hardware connection 162.

Input from analog sensors may go to an analog periodic task block 164via a hardware connection 163. Analog task 164 may be connected to sharememory 130 via a two-way connection 165. A control algorithm periodictask block 166 is connected to share memory 130 via a two-way data path167. A schedule period task 168 is connected to share memory 130 via atwo-way data path connection 169. Information flash management periodictask 170 may be connected by a two-way data path 171 to share memory130. A configParam(info) memory 172 may be connected via a two-way datapath 173 to information flash management periodic task 170. AuserSched(info) memory 174 may be connected via a two-way data path 175to information flash management task 170. Defaults(code) memory 176 maybe connected to information flash management task 170 via a one-way datapath 177.

A display periodic task block 178 may be connected to share memory 130via a data path 179. A keyscan memory 180 may be connected to displaytask 178 via a one-way data path 181 towards display task 178. Akeyboard scanner interrupt task 182 may be connected to keyscan memory180 via data path 183 in a direction towards keyscan memory 180.Keyboard scanner 182 may be connected to keyboard 45 via a two-wayhardware connection 184. Display periodic task 178 may be connected to adisplay memory 186 via a one-way data path towards display memory 186.The latter may be connected to liquid crystal display 38 via hardwareconnection 187.

FIG. 23 shows further detail of the “transmit-out” portion of the systemin FIG. 22. Send buffer memory 142 may be connected to send characterinterrupt task block 188 via a one-way data path 189 towards sendcharacter task 188. Task 188 may send out character information viahardware connection 147. Handshake related information may be receivedby send character task 188 via hardware connection 146. Connection 146also may go to handshake interrupt task 190. Handshake interrupt task190 is connected to send buffer memory 142 via a one-way data path 191towards send buffer 142. Data paths 189 and 191 may be represented bydata path 145, and the send character task 188 and handshake interrupttask 190 may be represented by send character interrupt task 144 in FIG.22. Further, realTimeClock task 135 may have a broader label of “othervariables” as the clock may be one of the variables.

The tables below summarize the usage of the relays for each sub-basetype and the type of equipment controlled (conventional or heat pump).The modulating output sub-base has two analog outputs in addition torelays. The sub-base type is detected by measuring the voltage set byresistor values on the sub-base. The following table shows the featuresfor conventional equipment of an air management system.

TABLE 32 Output (internal Sub-base1 Sub-base2 Sub-base3 Sub-baseModdesignation) Use As Use As Use As Use As Fan Fan Fan Fan Fan Heat1 Heat1 Heat 1 Heat 1 Heat 1 Cool1 Cool 1 Cool 1 Cool 1 Cool 1 Aux Aux or Auxor Aux or Heat3 Aux or Heat 2 Heat 2 or Heat3 or Cool3 or Cool2 Cool2 orCool3 (note 1 and 2) (note 1 and 2) (note 1 (note 1 and 2) and 2) Heat2n/a Heat2 Heat2 n/a Cool2 n/a Cool2 Cool2 n/a Heat3 n/a n/a Heat3/Cool4n/a Cool3 n/a n/a Cool3 n/a ModHeat n/a n/a n/a Modulating Heat ModCooln/a n/a n/a Modulating Cool

The designation “n/a” means that the item may not be available for thatsub-base configuration. The aux (auxiliary) relay normal function may beone of the following: time of day occupancy signal, economizer enable,dehumidifier hot gas, and simple dehumidification. An additional stageof heating or cooling may be configured using the aux relay.

There may be two analog outputs available when Sub-baseMod is used withthe thermostat. Microcontroller internal timers may be used to generatea pulse width modulation output. A low pass filter on the sub-base mayconvert the pulse width modulated outputs to analog current. Byconnecting an appropriate value resistor, the output may be converted tovoltage output. The cycle time may be set at 8 MHz/200 counts (i.e., thefrequency is 40 KHz and each counter pulse is 25 microseconds). The dutycycle may be set between 0 and 100 percent. There may be 200 steps inthe 0 to 100 percent control range.

Thermostat 11 may communicate with an external device such as a PersonalDigital Assistant (PDA), factory tester, PC based development tool, oran optional communicating sub-base. The sub-base in turn communicateswith other devices via a digital data network. There may be a softwareinterface between the thermostat and the external device, and thesub-base, including the protocol, and the data structures. There may bean external device and the communicating sub-base connected at the sametime. It is not necessary to communicate directly between the sub-baseand the external device. There may be a need to coordinate thecommunications flow from sub-base to thermostat and from external deviceto the thermostat. The object of the interface may be to shareinformation between the thermostat and the external device (e.g., PDA)or between the thermostat and a communicating sub-base using a simplelow cost protocol.

Communications between the sub-base or external device, and thethermostat may be via an asynchronous five wire connection. Theconnections between the external device and the thermostat may includean input to receive data (i.e., data flowing from the sub-base orexternal device to the thermostat), an output to transmit data (i.e.,data flowing to the external device or sub-base from the thermostat), aninput for handshake (i.e., used to tell the thermostat that it isacceptable to send data to the external device), a pass-throughconnection (i.e., an external service request which may be used by thePDA to request access to the receive data. The latter connection may bebetween the external device and the communicating sub-base and onlypasses through the thermostat. There may also be a circuit groundconnection.

Information may be passed between the thermostat and the external deviceusing asynchronous characters having one start bit, eight data bits, noparity bit and one stop bit. The start bit is a logic 0 input (i.e., 0volts) at the common hardware interface. The stop bit is a “logic 1”input (i.e., 3 volts).

The baud rate is 4800 baud. The maximum number of characters per messagemay be 11 characters. The limitation may be based on the fact that anentity that is exchanging information with the thermostat may not beable to process messages any larger than that at that rate.

The message format is shown below in table 33. The message may be 11bytes long. The least significant bit of each byte is sent first. The“variable number” byte is the first byte sent and the “CheckSum” is thelast byte sent. The same message format may be sent by the thermostatand the external device. The message length is fixed so that theexternal device will be most efficient on using processor timeresources. The processor may become inefficient if the message length isnot the same as the length of the message it is expecting.

TABLE 33 Variable nr 1 to 8 data bytes 0 to 7 fill bytes CheckSum

FIG. 23 shows the elements involved in providing communications with anexternal device. “Share” is a structure that may contain most of thethermostat global variables. Included in “share” may be configurationparameters, current status, and copies of inputs from the externaldevice. “Share” may be broken into “variables” for transfer to/from anexternal device. In addition “other variables” may be included in thelist of variables shared with the external device.

The receive buffer may contain room for four received messages, thenumber of buffers currently in use, a pointer to the buffer being usedto receive characters, a pointer to the next location to store areceived character, and the value of the partially calculated check sum.

The receive character interrupt routine may store characters into thereceive buffer as they are received via the hardware UART one characterat a time. A universal asynchronous receiver/transmitter (UART)controller may be the key component of the serial communicationssubsystem of the processor. The UART may take bytes of data and transmitthe individual bits in a sequential fashion. At the destination, asecond UART may re-assemble the bits into complete bytes. The receivecharacter also may detect the start of the message using the gapsbetween messages, calculate the checksum, update buffer pointer andcount when a valid message is received. If the buffer is full, thereceive character interrupt routine may ignore received messages.

The send buffer may contain room for four received messages, the numberof buffers currently in use, a pointer to the buffer being used to sendcharacters, a pointer to the next character to be sent, and the value ofthe partially calculated check sum.

The send character interrupt routine may send characters from the sendbuffer to the hardware UART one character at a time. It also maycalculate the check sum to send, put in four character gaps betweenmessages, and update buffer pointers as messages are completely sent.When the send buffer is empty, or the handshake line is not asserted atthe end of a message, the send character interrupt routine may turn itself off.

The handshake interrupt routine may run when the handshake line becomesasserted. If the send UART is turned off and there is data in a buffer,asserting the handshake line causes the first character of a ready sendbuffer to be sent via the UART.

The communications task may run every 100 milliseconds and perform thefollowing communication tasks. First, if there are any messages in thereceive buffer, it may reset the communications timer. If there are anymessages in the receive buffer, it may copy them to their destination inlocal RAM providing their class permits them to be copied. In 100 ms, itis possible to receive 3.2 messages. If there is any space in the sendbuffer, it may select the next variables to send to the external deviceand copy them to the send buffer until the send buffer is full. In 100ms, it is possible to send 3.2 messages. Receiving selected variablesmay cause a failure detect timer to be restarted. If a failure detecttimer times out, the variables may be reset to a default value. Failuredetect timers may be intended to provide fail safe operation of selectedfunctions. If an inUse signal is received with the re-programmer code,the communications task may turn off controlled equipment, saveconfiguration parameters and user schedule in INFO flash memory, andcall ProgramCodeFlash( ).

The alarmError signal may contain bits indicating that certain errorshave been detected in the thermostat and may be viewed via thecommunication port. Table 34 shows the various alarm fields that may beused in testing and diagnostics.

TABLE 34 What happens in the device on Method of displaying alarmErrorfield Meaning error error on the device almUsrScdCkSum User ScheduleCheck Sum Error. Current schedule continues to be Display will not allowthe Calculated when the user tries to used. user to select “yes” toretrieve the user schedule retrieve the saved user 0: User schedule wasretrieved schedule. It will display successfully “no” when the usertries to 1: User schedule was not retrieved change the selection tosuccessfully “yes” almCnfPrmCkSum Configuration Parameter Check Factorydefault configuration is No display action Sum Error. Calculated whenmains being used. power is restored or upon a reset almCnfPrmCkSum isset to zero 0: Configuration Parameters were when config1.installConfigis set to retrieved successfully from non- one by the installer.volatile memory. 1: Configuration Parameters were not retrievedsuccessfully from non- volatile memory. The factory defaultconfiguration parameters are being used instead. almSub-baseTypeSub-base type error. Read from the Thermostat relays and analog Nodisplay action sub-base resistive voltage divider in outputs are turnedoff. the sub-base 0: The sub-base is a valid sub-base type 1: Thesub-base is not a valid sub- base type almIOConfig Output configurationerror. In conventional mode, fan and only No display action Considerssub-base type, heat one stage of heating and cooling ispump/conventional application, enabled. If modulating sub-base ismaxCoolStgs, maxHeatStgs. connected, modulation is activated. 0: Theoutputs configuration is In heat pump mode, fan and only consistent withthe sub-base type one compressor (heating or cooling) selected isavailable. Auxiliary heat is not 1: The number of outputs available.Note: Modulating sub- configured exceeds the capability of base is notsupported (All outputs the sub-base to support them. turned off)errDischSensr Discharge sensor out of range or Discharge air temperaturelimiting Display shows “—” for the disconnected. will not be done.value. 0: Sensor value is OK. 1: Sensor is configured to function and isout of range or disconnected. errRemtSetPt Remote wall module set pointis out Remote setpoint offset of zero (0) is No display action. of rangeor disconnected. used. 0: Value is OK. 1: Remote wall module set pointis configured to function and is out of range or disconnected.errNetOdSensr Network Outdoor air sensor not There is no heat/coollockout. The Display shows “—” for the working. minimum heat/coolrecovery ramps value if the sensor is 0: Sensor value is OK. are used.invalid. 1: Sensor is configured to function See Note 1. See Note 1. butis not being updated by the network errOdSensr Remote Outdoor air sensornot There is no heat/cool lockout. The Display shows “—” for theworking. minimum heat/cool recovery ramps value if the sensor is 0:Sensor value is OK. are used. invalid. 1: Sensor is configured tofunction See Note 1. See Note 1. and is out of range or disconnected.errNetHumSensr Network Humidity sensor not There is no humidity control.Display shows “—” for the working. See Note 2. value if the sensor is 0:Sensor value is OK. invalid. 1: Sensor is configured to function SeeNote 2. but is not being updated by the network errRemtHumSensr RemoteHumidity sensor not There is no humidity control. Display shows “—” forthe working. See Note 2. value if the sensor is 0: Sensor value is OK.invalid. 1: Sensor is configured to function and is out of range ordisconnected. alarmError.errLoclHumSensr Local Humidity sensor notworking. There is no humidity control. Display shows “—” for the 0:Sensor value is OK. See Note 2. value if the sensor is 1: Sensor isconfigured to function invalid. and is out of range or disconnected. SeeNote 2. alarmError.errNetSpaceSensr Network space temperature sensorThere is no temperature control. Display shows “—” for the not working.See Note 2. value if the sensor is 0: Sensor value is OK. invalid. 1:Sensor is configured to function See Note 2. but is not being updated bythe network alarmError.errRemtSpaceSensr Remote space temperature sensorThere is no temperature control. Display shows “—” for the not working.See Note 2. value if the sensor is 0: Sensor value is OK. invalid. 1:Sensor is configured to function See Note 2. and is out of range ordisconnected. alarmError.errLoclSpaceSensr Local space temperaturesensor not There is no temperature control. Display shows “—” for theworking. See Note 2. value if the sensor is 0: Sensor value is OK.invalid. 1: Sensor is configured to function See Note 2. and is out ofrange or disconnected.

If a network sensor is configured for use, but invalid, then thethermostat processor may look for a valid sensor on the remoteterminals. If it is valid it may use the remote as the value. If theremote is also invalid, it may look at the local sensor. If it is validit may use the local sensor as the value. If all of them are invalid,then “invalid” may be reported as the sensor value and the display willshow “- - - ”. This allows the user to configure the network (or remote)as the primary sensor and have a backup in case the primary fails. Ifthe network sensor is configured and is invalid, it may report an alarmerror. If the remote sensor is configured and is invalid, it may reportan alarm error. If the local sensor is configured and is invalid, it mayreport an alarm error. In other words if the configured sensor isinvalid, then it may report an alarm error.

A factory test mode may be used to test the thermostat and a connectedsub-base. Components tested in the factory test mode may include keys inthe keypad (19 Keys), display segments, four relays on the thermostatboard, up to four relays on the sub-base, one wall module LED driver,two Digital inputs (i.e., occupancy sensor and one wall module bypasspush button switch), two analog outputs (plus up to two analog outputson the sub-base where the modulating sub-base is required), eight analoginputs (i.e., the local space temperature on thermostat, the remotespace temperature, the remote wall module set point control, the localhumidity sensor on sub-base, the remote humidity sensor, the outdoortemperature sensor, the discharge air sensor, and the sub-baseidentifier), and the communications port (for data in, data out, and thehandshake line).

The configuration parameters may be saved in INFO FLASH memory whenmains power has failed. There may be verification that when mains powerhas been restored, the configuration is also restored as saved. This maytest the circuitry that senses power failure and the power supplycapacitors ability to supply power for a few milliseconds while INFOFLASH memory is being written.

The following may not necessarily be tested by the software. One item isthe super capacitor ability to supply power to the device for the ratednumber of hours after mains power has failed. Clock frequency may beanother. A general recommended approach to final factory test may be asfollows. Lock thermostat with sub-base into test fixture. Apply power(24 volts AC—set voltage at low end of 24 VAC tolerance). The displayshould initially turn on all segments after mains power up. The testfixture may communicate with thermostat via communications port and putsit into the factory test mode. The test fixture may press the keys oneat a time. Each key may cause certain actions (e.g., provide a LDCdisplay pattern, turn on one relay, set the analog output to certainvalues, and so on). A vision system may watch the display and rejectunits having an invalid display. The test fixture may sense digital andanalog outputs for proper operation. Simultaneously, the test fixturemay connect various analog sensors to the analog inputs and monitors thesensed analog values via the communications port. Simultaneously thetest fixture may turn on and off the various analog inputs and monitorsthe sensed digital states via the communications port.

One may turn off the power. After 5 seconds one may cycle the power backon. Then one may verify that, via the communications port, theconfiguration was read correctly from INFO FLASH memory into RAM uponpower up. There is no need to enter factory test mode. The displayshould initially turn on all segments after mains power up. Turn offpower and report success or failure. Remove thermostat from testfixture. There may be a separate test sequence or just one test sequencefor each sub-base type. Also, one may test the outputs and inputs on thethermostat even if they are not present in the particular sub-base typebeing tested.

To read and view the state of the inputs, one may read the followingvariables via the communications port. The variables may be read in thenormal operating mode or in the factory test mode. In the factory testmode, a filter is turned off so that the analog value changes morerapidly in the factory test mode. Table 35 shows the various variablesand what the typical test values may be.

TABLE 35 Variable Reads Typical Values rawAnalogA.remoteHum RemoteHumidity 14880 when input is 10.00 volts rawAnalogA.localHum LocalHumidity 5460 when input is 1.00 volts rawAnalogA.odTemp OutdoorTemperature 13124 when input is connected to 3000 ohm resistorrawAnalogA.discTemp Discharge Air Temperature 3796 when input isconnected to 10,000 ohm resistor rawAnalogB.remoteStPt Remote Set point11228 when input is connected to 5500 ohm resistorrawAnalogB.sub-baseSel Sub-base Selection 8600 when input is connectedto 10200 ohm resistor rawAnalogB.remoteSpaceTemp Remote SpaceTemperature 3796 when input is connected to 10,000 ohm resistorrawAnalogB.localSpaceTemp Local Space Temperature 3796 when input isconnected to 10,000 ohm resistor status1.oocSensor State of OccupancySensor TRUE when occupancy sensor input is shorted FALSE when occupancysensor input is open status1.bypassTime State of Remote Bypass Set to180 minutes when the remote bypass input is shorted to ground.Decrements every minute when the remote bypass input is open

To enter the factory test mode, one may set manMode.manualMode toFactoryTest. In the factory test mode the following may occur. Thealgorithmic control of the analog and digital outputs is turned off.Instead, the outputs are controlled by the internal factory testsoftware. Every 15 seconds, manMode should be sent to the thermostat orthe thermostat will return to Run mode. The LCD and display no longerfunction in the normal manner. Pressing a key pad button may cause thefollowing action. The output and pattern do not change until another keyis pressed.

One may verify that FLASH was written correctly upon mains power fail.When mains power fails, the configuration parameters and schedules arewritten to INFO FLASH memory as soon as the power failure is detected.The successful writing of INFO FLASH memory generally depends on thecharge remaining in the filter capacitors and the super cap.

During the write process at power fail, the following items may occur.First, the check sum of the configuration parameters is calculated.Second: the FLASH is erased. Third, configuration parameters are copiedinto INFO FLASH memory, and finally, the check sum of the configurationparameters (including schedules) are written to INFO FLASH. Upon returnof mains power, if the stored check sum and the calculated check sumagree, the configuration parameters are copied from INFO FLASH intooperating RAM. If the calculated and stored check sums do not agree,then the factory default settings are copied into the operating RAM.Also, if they do not agree, alarmError.almCnfPrmCkSum is set to TRUE.

In the factory, when the device is first powered up, INFO FLASH will nothave any useful information stored in it, so the calculated check sumwill not agree with stored check sum, and alarmError.almCnfPrmCkSum willbe set to TRUE. However, when the unit is powered down the first time,INFO FLASH may be written correctly (assuming the power supply isworking correctly) and upon power up alarmError.almCnfPrmCkSum will beset to FALSE indicating a successful writing of INFO FLASH. The factorytester should check alarmError.almCnfPrmCkSum after powering the unit upthe second time.

One may verify the microprocessor reset button. When the reset button ispressed, the microprocessor will restart itself and the display willtemporarily turn on all its segments. Other side effects may includesuch things as time is lost, alarm bits reset, and all RAM statusvariables are reset to their default values until the processor updatesthem to their correct values. If the configuration or schedule has beenchanged, the changes will be lost.

The manual mode is intended for field use. When the thermostat is inmanual mode, the equipment is controlled manually via the communicationsport. Algorithmic control of the equipment is turned off. The state ofthe eight relays is controlled individually. The modulated heat and cooloutputs are controlled independently. Returning from factory test ormanual mode to run mode causes a reset.

The error count variable, errCnt, applies to the diagnostics of thesystem. The errCnt.rxCkSumErrCnt may relate to receiving messages fromthe PDA, tcomm, or the sub-base. The message may include a check sum.Thermostat 11 may calculate the check sum and compare it with the checksum in the received message. The errCnt.rxCkSumErrCnt may be incrementedevery time the calculated check sum does not match the receivedchecksum. Check sums may not match if the receiver receives a bitincorrectly or if the start of message at the receiver was receivedincorrectly. This count might be incremented once in a while but therate should be low, such as one or two counts in a day.

The errCnt.rxBufferFullCnt relates to receiving messages from the PDA,tcomm, or the sub-base. There may be a receive buffer that has space forfour received messages. Received messages may be received usinginterrupts and placed into the buffer. Once every 100 ms, the Comm. taskmay run, read the messages and clear the buffer. If a message isreceived and there is not enough space in the buffer for more messages,then the message may be lost and errCnt.rxBufferFullCnt may beincremented by one. The latter should always be zero. It takes about 25ms to send one message.

The errCnt.wdtCnt may be incremented if the program starts over and thereason for the reset was a watchdog timer time out (i.e., the programwas lost and the watchdog timer caused a reset). The errCnt.wdtCntshould always be zero. Failures may occur due to hardware problems(e.g., reading memory incorrectly) caused by electrical noise which isnot very likely because memory is on the same chip as the processor.Failures may also occur due to a code that goes into an endless loop ora corrupted stack after a return from a subroutine call or the like. Thewatch dog timer may be “hit” once every 100 ms at the end of the tasksfor each 100 ms time slot.

The errCnt.flashViolations may be incremented whenever there is a flashviolation interrupt. Flash violation may occur if code is running fromflash memory and tries to write the same flash memory module at the sametime. The errCnt.flashViolations should always be zero. Flash writes mayoccur during re-programming, power down, and update of user schedule.

Each display state is listed in the following table 36. A descriptionfor each state and a table listing actions for each key press follows.In general, a change of display state occurs if a key is pressed orbecause no key has been pressed for a defined period of time and theinformation for the previous state is saved. Exceptions may be listed inthe description for each state.

TABLE 36 State Keypress Description dsRunNormal keyRun Display dsHeatOcckeyHeatOcc Set Occupied Heat Setpoint dsCoolOcc keyCoolOcc Set OccupiedCool Setpoint dsHeatNotOcc keyHeatNotOcc Set Not Occupied Heat SetpointdsCoolNotOcc keyCoolNotOcc Set Not Occupied Cool Setpoint dsSetDaykeySetDay Set Day of Week dsSetTime keySetTime Set Time of Day dsTempOcckeyTempOcc Set Temporary Occupied Override dsTempNotOcc keyTempNotOccSet Temporary Not Occupied number of days dsSetSched keySchedDay,keySchedOcc, or Set Schedules keySchedNotOcc dsSchedCopy keySchedCopyCopy schedule from one day to another dsTemStpt keyInfo, keyUp, orkeyDown Set Temporary Setpoint dsInfo keyInfo Display Informationscreens dsInstaller keyRun and keySchedCopy Set Installer configurationoptions dsTestMode keyRun, keySystem, and keyFan Enter Test Mode (nodelays of heating and cooling stages) dsGetFactorySched keyRun andkeySchedClear Restore factory schedules from flash memory to currentschedules dsGetUserSched keyInfo and keySystem Restore user definedschedules from flash memory to current schedules dsSaveUserSched keyInfoand keySchedCopy Save current schedules to user define schedules inflash memory dsFactoryConfig keyRun and keySchedClear Restore factoryconfiguration dsShowAll Power up Show all LCD segments for 2 secondsdsShowLocked — Display ‘LOCKED’ or ‘MANMODE’ for 1 second

The test mode may be the dsTestMode. Pressing the combination key press(‘scheduled day’, ‘schedule occ’ and ‘scheduled unocc) for ‘Test Mode’may allow the user to disable time delays between stages to minimizetime to test the wiring and operation. The following information may bedisplayed: ‘Set’ segment--‘NO TEST’.

Pressing the Up and Down keys may toggle the selection between ‘IN TEST’and ‘NO TEST’ and save to the variable share.sysMode.disabledelays. The‘IN TEST’ will disable delays. ‘NO TEST’ is normal operation. After 10minutes with no key pressed, the thermostat will change back to normaloperation or ‘NO TEST’. The following is the test mode table for thedsTestMode.

TABLE 37 Keypress Actions: keyNone Increment NoKeyPressTimer, Changestate to dsRunNormal after 5 minutes, Set share.sysMode.disableDelays to‘NO TEST’ after 10 minutes. keyDown Toggle share.sysMode.disableDelays(‘IN TEST’ or ‘NO TEST’) keyDown & keyHold N/A keyInfo Change state todsInfo keyUp Toggle share.sysMode.disableDelays (‘IN TEST’ or ‘NO TEST’)keyUp & keyHold N/A keyHeatOcc Change state to dsHeatOcc keyCoolOccChange state to dsCoolOcc keyHeatNotOcc Change state to dsHeatNotOcckeyCoolNotOcc Change state to dsCoolNotOcc keySetDay Change state todsSetDay keySetTime Change state to dsSetTime keyTempOcc Change state todsTempOcc keyTempNotOcc Change state to dsTempNotOcc keySchedDay Changestate to dsSetSched Initialize sbDisplayDay to current day of weekInitialize sbDisplayEvent to event Occupied 1 keySchedOcc Change stateto dsSetSched Initialize sbDisplayDay to current day of week InitializesbDisplayEvent to event Occupied 1 keySchedNotOcc Change state todsSetSched Initialize sbDisplayDay to current day of week InitializesbDisplayEvent to event Not Occupied 1 keySchedClear N/A keySchedCopyN/A keyRun Change state to dsRunNormal.* keyInstaller Change state todsInstaller.* keySaveUserSched Change state to dsSaveUserSchedkeyGetUserSched Change state to dsGetUserSched keyGetFactorySched Changestate to dsGetFactorySched *One may set the share.status1.bypassTime andshare.status1.daysLeftKeypadHoliday to 0.Thermostat 11 control algorithm may provide for control of various kindsof commercial HVAC equipment. More specifically it may be designed tocontrol constant volume packaged roof top units used for single zonespace temperature conditioning. A provision may also be provided toreduce humidity in the zone if it exceeds a high limit. Configurationparameters may allow for the control to be for single stage, multistageor modulating heating and cooling in conventional or heat pump units.The control is capable of automatically switching between heating andcooling as required if AUTO is selected as the run mode. The fan and anauxiliary output may also be controlled depending on configurationchoices.

FIG. 24 shows an algorithm module 200 overview. Algrm( ) function 202may be connected to timers and static variables memory 204 via a two-waydata path 203, and connected to a share.status 1,2,3,analog memory 206via a two-way data path 205. Algrm( ) function 202 may be connected to aCycler( ) function 208 via a one-way data path 207 towards Cycler( )function 208. Cycler( ) function 208 may be connected to timers andstatic variables via a two-way data path 209. Algrm( ) function 202 maybe connected to a Set_outputs( ) function 210 via a one-way data path211 towards Set_outputs( ) function 210. Algrm( ) function 202 may beconnected to an Aux_pt( ) function 212 via a one-way data path 213towards Aux_pt( ) function 212. Share.status 1,2,3,analog memory 206 maybe connected to Set_outputs( ) function 210 via a two-way data path 215,and connected to Aux_pt( ) function 212 via a two-way data path 217.

Algrm( ) function 202 may be connected to TempControlInit( ) andTempControlOff( ) functions 216 via a one-way data path 221 towardsfunctions 216. Algrm( ) function 202 may be connected to an Auto_chng( )function 218 via a one-way data path 223 towards function 218.Share.config memory 220 may be connected to Algrm( ) function 202 via aone-way data path 225 towards function 202. Share.config memory 220 maybe connected to Cycler( ) function 208 with a one-way path 227 towardsfunction 208. Share.config memory 220 may be connected to Aux_pt( )function 212 via a one-way data path 229 towards function 212.Share.config memory 220 may be connected to Fan_Control( ) function 214via a one-way data path 231 towards function 214.

Share.setPts memory 222 may be connected to Auto_chng( ) function 218via a one-way data path 233 towards function 218. Share.setPts memory222 may be connected to Cycler( ) function 208 via a data path 235towards function 208.

Cycler( ) function 208 may be connected to an ErrorCalc( ) function 224via a one-way data path 237 towards function 224. A Share.auxSetPtsmemory 226 may be connected to ErrorCalc( ) function 224 via a one-waydata path 239 towards function 224. ErrorCalc( ) function 224 may beconnected to a Gain_Calc( ) function 226 via a one-way data path 239towards function 226. A Share.gainHeat and Share.gainCool memory 228 maybe connected to Gain_Calc( ) function 226 via a one-data data path 243towards function 226.

Algrm( ) function 202 may be called every 10 seconds from the operatingsystem task scheduler. It may read the commanded system mode and spacetemperature sensor input to arbitrate the effective run mode ofthermostat 11. Also, the configuration may be read to determine whichcontrol features to perform and the resultant “logical” control commandswhich are generated and written to the status RAM (random access memory)variables. The commands may be logical in that they generically list therun mode (heat or cool) and the number of stages of heat and cool thatshould be active. A separate function called from the task manager maybe responsible for reading the logical control output commands fromstatus RAM and driving the physical outputs appropriately based onsub-base type and output configuration.

Looking further at the Algrm( ) 202 function overview, one may note thatif the manual mode command is factory test or manual, or the manual modecommand is run and the system mode command is system switch=off, or thespace sensor is invalid, then the logical control outputs may be set toinitialization values and no other action is taken. If the manual modecommand is run and the system mode command is system switch=heat orcool, then Cycler( ) function 208 may be called with the effective modeset accordingly so that the proper set points may be used to calculatethe space temperature error and its sign. If the manual mode command isrun and the system mode command is system switch=auto, then Auto_chng( )function 218 may be called to calculate the proper effective mode (heator cool) and thus the proper set points before Cycler( ) function 208 iscalled. After Cycler( ) 208 runs, then Set_outputs( ) function 210 maybe called to take the Cycler( ) function 208 output and, based on theconfiguration, set the control status variables appropriately. Likewise,based on the configuration and the Cycler( ) function 208 output status,the Fan_Control( ) function 214 and the Aux_pt( ) function 212 may becalled to set their logical output values per the control schemeselected. All the timers associated with the control algorithm may bekept in this function. These may be the four stage timers (one perpossible stage), the interstage timer, the start-up fan delay timer andthe dehumidify flag timer. When the disable delay (“test mode”) isselected, all of the control algorithm timers that delay action may bekept cleared.

Cycler( ) function 208 may be implemented in the control block diagramof FIG. 25. An output 245 from a set point 230 may go to a junction 232.An output 247 from a sensor 234 may go to junction 232. Output 247 maybe subtracted from output 245 at junction 232 to result in an errorsignal output (Err) 249 which may go to the inputs of a

${\;^{``}{Kp}/{Ti}}{\int_{0}^{7}{({Err})\ {\mathbb{d}t^{"}}}}$function block 236, a “Kp*Err” function block 238 and a“Kp*Td*(dErr/dt)” function block 240. Outputs 251, 253 and 255 fromfunction blocks 236, 238 and 240, respectively, may be added at junction242 to result in a total error (TotErr(%)) output 257 in terms ofpercentage. Output 257 may go to a modulating driver 244.

In the preferred embodiment, output 257 may also go to an input of astager block 446. Stager block 446 may convert and proportionally adjustthe cycling rate for the digital stages, and control the number ofstages requested based on the configuration of cycle rate, the number ofstages configured, sensed temperature, time delay minimum time and totalerror. Output 465 of block 446 may provide a “stages on” signal for theindividual heating and cooling stages.

Along with minimum on time, minimum off time and interstage delay timesmay also be enforced before a stage is added or subtracted from thestages active command that is the output of this function. This functionalso may set the status of the dehumidify flag (dehumidActive). It mayuse both a minimum on timer and a 5 percent hysteresis for turning offthe flag once it is set. If the sensed humidity is above the programmedhigh limit the flag may be set. Only after the humidity is 5 percentbelow the high limit set point for the min on time will the flag bereset. The minimum on time may also be variable based on the occupancymode when the high humidity set point reset strategy is configured. Ifthe high humidity set point reset strategy is configured, and thecurrent occupancy mode is unoccupied, the dehumidActive flag min on timemay be 20 minutes; at all other times it may be set to 5 minutes.

The ErrorCalc( ) function 224 may call the Gain_calc( ) 226 to convertthe gain configuration parameters into the proper units and fixed pointoffset to be directly used in the PID error calculation. It then maycalculate the base PID error as TotErr 257 in percent. This may be usedto drive the modulating output if it is configured. The secondaryfunction performed may be the discharge air limit function. If thedischarge air limit function is active then if the discharge air iswithin 5 degrees F. of the limit the TotErr is reduced proportionallydown to 0 as it approaches the limit. If the discharge temperature isover the limit, TotErr is set to 0, integration is stopped and a flag isset to enable Cycler( ) 208 to turn off a stage and prevent other stagesfrom coming on.

Thermostat 11 may communicate with an external device 56 and an optionalcommunicating sub-base 14. External device 56 could be a personaldigital assistant (PDA) 12, factory tester, or a PC-based developmenttool. Only one external device might be connected at a time. Sub-base 14in turn may communicate with other devices via a digital data network.It may be possible to have an external device 56 and communicatingsub-base 14 connected at the same time. There may be no need tocommunicate directly between sub-base 14 and external device 56. Theremay be coordination of the communications flow from sub-base 14 tothermostat 11 and from external device 56 to thermostat 11.

One object of the interface is to share information between thermostat11 and the external device (PDA) or between thermostat 11 and acommunicating sub-base 14 using a simple low cost protocol.Communications between sub-base 14 or external device 56, and thermostat11 may be typically via an asynchronous five wire connection. FIGS. 26and 27 reveal similar connections. The connections between externaldevice 56 and thermostat 11 may include an input to receive data (i.e.,data flowing from the sub-base or external device to the thermostat) online 301, an output to transmit data (i.e., data flowing to the externaldevice or sub-base from the thermostat) on line 302, an input tohandshake (i.e., used to tell the thermostat that it is acceptable tosend data to the external device) on line 303, and a pass throughconnection for an external service request (i.e., used by the PDA torequest access to the receive data) on line 304. The latter connectionmay be between external device 56 and communicating sub-base 14, andonly pass through thermostat 11. Another connection may be a circuitground on line 305. A 15 volt supply line 306 may be present. Lines 301,302, 304 and 305 may be connected to external device 56 via a connector310.

Information may be passed between thermostat 14 and external device 56using asynchronous characters having one start bit, eight data bits, noparity bit and one stop bit. The start bit is a logic 0 input (0 volts)at the common hardware interface. The stop bit is a “logic 1” input (3volts). The baud rate may be 4800 baud.

Data may be sent in both directions at the same time (a full-duplexoperation). Thermostat 11 may receive data at any time. There may bethermostat transmitter flow control via handshake circuit. Generally,data may be sent from thermostat 11 only when the handshake input isasserted. Communicating sub-base 14 may control the flow of data to it.External device 56 may send and receive at the same time. When externaldevice 56 requests service by asserting an external service request,communicating sub-base 14 may assert a handshake line 303 so that thedata may be sent continuously by thermostat 11. If sub-base 14 isnon-communicating, handshake line 303 may be asserted continuously, sothat an external device 56 may send and receive data at the same time.FIGS. 26 and 27 show a communicating sub-base 14 and a non-communicatingsub-base which is blanked out to indication non-functionality.

Thermostat 11 may receive flow control via an external service requestcircuit line 304. Either communicating sub-base 14 or external device 56may send data to thermostat 11 at any time. However, both typically donot send data at the same time. The external service request circuit vialine 304 may be used to select the active sender on the thermostat 11receive circuit.

When the external service request is not asserted, communicatingsub-base 14 may be allowed to communicate with thermostat 11 in bothdirections, using the handshake circuit via line 303 to control dataflow from thermostat 11 to sub-base 14. When external device 56 assertsexternal service request (using the RTS circuit on the external device'sport) via line 304, communicating sub-base 14 may be allowed to completethe message it is currently transmitting, before it asserts handshakeline 303 and ceases communications with thermostat 11. External device56 then may communicate with thermostat 11 in both directions untilexternal device 56 unasserts the external service request. Note thatsub-base 14 typically does not listen to transmit data while externalservice request is asserted since handshake is also asserted. Whensub-base 14 is a non-communicating sub-base, then external device 56 maystill assert an external service request, and wait for at least onemessage time before sending on the thermostat 11 receive circuit vialine 301.

The handshake input to thermostat 11 microprocessor 61 may controlwhether or not thermostat 11 sends information to external device 56.When sub-base 14 is a non-communicating sub-base, the handshake inputmay be pulled to “active” by a resistor on thermostat 11. Thermostat 11may send information continuously on TXD of line 302, one message afteranother with the required gap between messages. When sub-base 14 is acommunicating sub-base, the handshake input may be set to active bysub-base 14 whenever it is able to receive a message. Thermostat 11 maysend information on TXD line 302 whenever the handshake input is active.

When a communicating sub-base 14 is connected, then sub-base 14 mayperiodically send the sub-base variable to thermostat 11, withsub-base.connected=1. An external device 56 may never send sub-base 14to thermostat 11. This flag may let an external device 56 know that acommunicating sub-base 14 is present.

The inUse (i.e., in use) variable may be used to indicate that an “inUsesession” with an external device, a remote network tool or network workstation is in progress. The inUse.by may also be used to initiateprogramming flash memory. An “inUse session” may involve any of thefollowing: an external device (Palm Personal DigitalAssistant)−inuse.by=2; a read/write thermostat configuration using aPDA; a read/write schedule using a PDA; a status report via a PDA(optional at the discretion of the PDA designer); and manual control viaa PDA.

An “inUse session” may be started by either the external device or thecommunicating sub-base when the other device (i.e., a sub-base orexternal device) could interfere with a process begun by the firstdevice. The external device may have priority over the sub-base. If asub-base has initiated an “inUse session”, the external device maycancel the sub-base session and initiate its own session. If an externaldevice has already established an “inUse session”, the sub-base (and itsassociated network tool) may not be allowed to start an “inUse session”.

The external device located next to the thermostat should have priorityover a network tool that may be located in another room or even hundredsof miles away. Some related “inUse Session” scenarios may or may notinvolve some of the following examples. For instance, it may not benecessary for the external device to start an “inUse session” to justread any variables. It may not be necessary for the sub-base to start an“inUse session” just to read any variables or write sub-base,comSchedOcc, comTimeIn, sysMode, or comIn. All of these variables may beeither overhead variables (sub-base) or connected to some other networkvariables that may be bound to other devices.

It may be necessary for the external device to start an “inUse session”to read the varCONFIG variables, allow a user to modify them, write themto the thermostat, and then monitor their effects. That any time the PDAis connected to the thermostat, and the PDA is actively performing theHoneywell Palm software, it should start an “inUse session” and setmanMode to 0. The external device may start an “inUse session” bywriting inuse.by=2. Table 38 may provide more “inUse session details.

TABLE 38 inUse.by Meaning Communicating sub-base External Device 0 Notin an “inUse session” May send any variables to the Variables may not besent to the thermostat. thermostat except for inUse. 1 The remotenetwork is in an May send any variables to the Variables may not be sentto the “inUse session” with the thermostat. thermostat except for inUse.thermostat via the Note: When nviInUse (a network communicating sub-basevariable) is updated to non-zero by a network tool, and inUse is 0, thenthe sub-base writes, inUse, by =1. 2 The external device (such as a Maysend only varWRITE class May send any variables to the PDA) is in an“inUse session” variables to the thermostat (except thermostat. withthermostat manMode and inUse). Note: The sub-base sets nviInUse (ane-bus mechanism variable) to 64129 when it sees that inUse, by is 2 toprevent a network tool from attempting to put the thermostat into manualmode or commission the device. 3 The flash programmer is When theexternal device is the re- External device uses the re- requesting tore-program the programmer, the sub-base may not programmer protocol todown load thermostat firmware send or receive any thing. the memoryimage. The sub-base may re-program the When the sub-base is thermostatusing the re-programmer reprogramming the thermostat, protocol. theexternal device should be disconnected or disabled.

Table 39 provides variable information relating to the alarm errorsystem.

TABLE 39 Variable Description and Notes VarNamefields.txt User ScheduleCheck Sum Error. alarmError.almUsrScdCkSum Calculated when the usertries to retrieve the user schedule 0: User schedule was retrievedsuccessfully 1: User schedule was not retrieved successfullyConfiguration Parameter Check Sum alarmError.almCnfPrmCkSum Error.Calculated when mains power is restored or upon a reset 0: ConfigurationParameters were retrieved successfully from non-volatile memory. 1:Configuration Parameters were not retrieved successfully fromnon-volatile memory. The factory default configuration parameters arebeing used instead. Sub-base type error. Read from the sub-alarmError.almSub-baseType base resistive voltage divider In the sub-base 0: The sub-base is a valid sub-base type 1: The sub-base is not avalid sub-base type Output configuration error. ConsidersalarmError.almIOConfig sub-base type, heat pump/conventionalapplication. maxCoolStgs, maxHeatStgs. 0: The outputs configuration isconsistent with the sub-base type selected 1: The number of outputsconfigured exceeds the capability of the sub-base to support them.Discharge sensor out of range or alarmError.errDischSensr disconnected.0: Sensor value is OK. 1: Sensor is configured to function and is out ofrange or disconnected. Remote wall module set point is out ofalarmError.errRemtSetPt range or disconnected. 0: Value is OK. 1: Remotewall module set point is configured to function and is out of range ordisconnected. Network Outdoor air sensor not alarmError.errNetOdSensrworking. 0: Sensor value is OK. 1: Sensor is configured to function butis not being updated by the network Remote Outdoor air sensor notworking. alarmError.errOdSensr 0: Sensor value is OK. 1: Sensor isconfigured to function and is out of range or disconnected. NetworkHumidity sensor not working. alarmError.errNetHumSensr 0: Sensor valueis OK. 1: Sensor is configured to function but is not being updated bythe network Remote Humidity sensor not working.alarmError.errRemtHumSensr 0: Sensor value is OK. 1: Sensor isconfigured to function and is out of range or disconnected. LocalHumidity sensor not working. alarmError.errLoclHumSensr 0: Sensor valueis OK. 1: Sensor is configured to function and is out of range ordisconnected. Network space temperature sensor notalarmError.errNetSpaceSensr working. 0: Sensor value is OK. 1: Sensor isconfigured to function but is not being updated by the network Remotespace temperature sensor not alarmError.errRemtSpaceSensr working. 0:Sensor value is OK. 1: Sensor is configured to function and is out ofrange or disconnected. Local space temperature sensor notalarmError.errLoclSpaceSensr working. 0: Sensor value is OK. 1: Sensoris configured to function and is out of range or disconnected.

The thermostat configuration may be identified and then thecommissioning process may be run through valid operational modes withinputs and set points temporarily manipulated while waiting for thedelays built into the controller to verify operation. The PDA basedOnline Diagnostics may automatically discover the thermostatconfiguration, turn off normal controller delays, temporarily overridesensor inputs and set points, verify proper output action includingmonitoring the discharge air temperature for the resulting temperaturebehavior based on the equipment stages activated.

Problems discovered may be reported, automatically recorded and theoriginal operating parameters may be restored. This means that lessexpertise may be required by the technicians sent to install and troubleshoot thermostat installations

To begin the commissioning startup, the user may tap on the commissionbutton on a PDA screen as shown in FIG. 28 a. The next screen may promptthe user to connect the PDA 12 serial port to thermostat 11, as in FIG.28 b. Then the configuration tool (i.e., PDA 12) may upload thethermostat model and current configuration from the thermostat. Acommission summary screen appears as revealed in FIG. 28 c. This screenmay appear after an analysis of the thermostat configuration. Navigationthrough the commissioning process by the user may be accomplished withthe “Back” and “Next” buttons. The diagnostics may be executed in alogical order of sensors, fan/auxiliary process, cooling process andheating process. The status of each step of the diagnostics process maybe reported as “OK”, “UnTested” or “Failed”. An error summary may reportknown problems (via thermostat diagnostic messages) and summarize allsession related messages.

The “Next” button may navigate the user to the sensors screens shown inFIGS. 29 a-29 f. In FIG. 29 a, the sensors screen may summarize thestatus of sensor/input diagnostics. Sensor data may be displayed in acontext sensitive format using the actual thermostat model andconfiguration data to mask irrelevant sensor tests. Of the buttons onthe screen, the “Update” button may update sensor data values, “Back”button may navigate to the previous screen, “Next” button may navigateto the “Fan” screen, and the “Test” button may initiates the automaticsensor diagnostics test sequence.

As a result of tapping the Test button on the sensors screen, one mayget a reading testing the room temperature data value which may beconfirmed or not by tapping the “Pass” or “Fail” button on the screen ofFIG. 29 b, respectively. As a result of tapping the “Testing Room Temp”Pass button, the diagnostics may move to the remote SetPoint testsequence, which begins with the screen in FIG. 29 c. The user may tapthe “OK” button after positioning the remote SetPoint knob to the fullCCW position. As a result of tapping the Testing Remote SetPt OK button,the diagnostics tool may validate the Remote SetPt value at full CCW, asindicated in the screen of FIG. 29 d. Then one may be instructed toposition the remote SetPoint knob to the full CW position. As result oftapping the Testing Remote SetPt OK button, the diagnostics tool mayvalidate the Remote SetPt value at full CW. Then the user may tap the OKbutton in the screen of FIG. 29 e to proceed with remaining sensordiagnostics. In a similar fashion, all of the sensor inputs may bevalidated. At the end of the sensor diagnostics sequence, configurationtool 12 may indicate the status of all relevant (hardware model and userconfiguration) sensors, as in the screen of FIG. 29 f. All Errormessages may be recorded on the diagnostics summary screen.

The user may tap the Next button to navigate to the Fan/Auxiliary screenof FIG. 30. The Fan/Auxiliary Equipment screen may summarize the statusof the Fan/Aux output diagnostics. Output data may be displayed in acontext sensitive format using the actual thermostat model andconfiguration data to mask irrelevant output tests. Tapping the Updatebutton may update the data values. The Back button may navigate the userto the previous screen. The Test button may initiate the automaticFan/Aux diagnostics test sequence. The Next button may navigate the userto the first cooling screen in FIG. 31 a.

The Cooling Equipment screen may summarize the status of the coolingoutput diagnostics. Output data may be displayed in a context sensitiveformat using the actual thermostat model and configuration data to maskirrelevant output tests. In this screen the Update button may updatedata values, the Back button may navigate to the previous screen, thetest button may initiate the automatic Cooling diagnostics testsequence. The Next button may navigate the user to the Heating screen.In FIG. 31 b, the screen asks whether it is safe to start the fan. Andif so, then the Yes button may be tapped and a screen of FIG. 31 c mayappear. The user may tap the Test button on this screen and confirm thatthe fan is running by tapping the Pass button. The next screen to appearmay be that of FIG. 31 d, asking if it is safe to start the coolingstages. The user may tap “Yes” to confirm that it is safe to start thecooling stages. The screens of FIGS. 31 e and 31 f may appear,respectively. Here, configuration tool 12 may collect and analyze data.The data collected may include the time interval on the progress line,the entry and discharge air temperatures over the time interval and thecooling coil delta temperature which may be the difference between thecoil entering and discharge air temperatures. After this process, tool12 may validate the cooling stage under test as in the screen of FIG. 31g. All of the remaining stages may be likewise checked out. FIG. 31 hshows a completion of the cooling equipment validation.

Tapping the Next button, one may get the Heating Equipment screen ofFIG. 32 a, which may begin with the check-out of the heating stage 1.The Heating Equipment screen may summarize the status of heating outputdiagnostics. Output data may be displayed in a context sensitive formatusing the actual thermostat model and configuration data to maskirrelevant output tests. On this screen, the Update button may updatedata values, the Back button may navigate the user to the previousscreen, and the Next button may navigate to the summary screen. The Testbutton may initiate the automatic heating diagnostics test sequence,which may start with the screen in FIG. 32 b. The user may tap “No” toindicate that fan airflow is not required for stage 1 heating. Suchairflow may be typical for baseboard heat installations. The next screenmay be that in FIG. 32 c asking whether it is safe to activate theheating stage contact. The user may tap “Yes” to confirm thatactivation. That heating stage may be turned on, which is indicated bythe screen of FIG. 32 d. After checking to see in the heating stage isactually on, the user may then tap “Pass” to validate the stage 1heating. A screen of FIG. 32 e may next appear indicating that theheating tests have been completed. Wiring and connections between thecontrols and fan, heating, cooling, air flow process, interfaces andother items may be tested and validated.

FIG. 33 is a flow diagram of an illustrative diagnostic test sequencefor a thermostat system. In block 351, one may connect PDA 12 tothermostat 11 and upload the configuration identification as in block352. The normal controller delays may be turned off as in block 353.Block 354 shows the sensor inputs and set points being overridden. Thenthe sensors may be tested and the set points checked in block 355. Thefan/auxiliary process may be tested in block 356. The cooling processmay be tested in block 357 and the heating process may be tested inblock 358. Then the noted failures, errors and dysfunctions ofthermostat 11 may be displayed on PDA 12 as in block 359. In block 360,diagnostic solutions may be presented.

Although the invention has been described with respect to at least oneillustrative embodiment, many variations and modifications will becomeapparent to those skilled in the art upon reading the presentspecification. It is therefore the intention that the appended claims beinterpreted as broadly as possible in view of the prior art to includeall such variations and modifications.

1. A thermostat system comprising: a configuring device; and a pluralityof thermostats for air management systems, respectively; and athermostat of the plurality of thermostats can provide modulated controlof an air management system and discrete control of the same airmanagement system or another management system; and wherein: theconfiguring device may upload, store, modify and/or download one or moreconfigurations of the plurality of thermostats; and each configurationmay be modified by changing: parameter settings; schedules of parametersettings; and/or modulated controls for heating stages and coolingstages.
 2. The system of claim 1, wherein each air management system mayhave a plurality of zones.
 3. The system of claim 1, wherein theconfiguring device has various configurations that may be downloaded tothe thermostats of the air management systems at different locations. 4.The system of claim 3, wherein the configuring device is a commerciallyavailable computer.
 5. The system of claim 3, wherein the configuringdevice is a personal digital assistant.
 6. The system of claim 5, thepersonal digital assistant is selected from group of devices consistingof a Palm™.
 7. A thermostat system comprising: a configuring device; anda plurality of thermostats, each thermostat having at least oneconfiguration for an air management system; and a thermostat of theplurality of thermostats can provide modulated control of an airmanagement system and discrete control of the same air management systemor another management system; and wherein the configuring device mayupload one or more thermostat configurations and perform diagnostics onthe configuration.
 8. The thermostat system of claim 7, wherein thediagnostics performed by the configuring device include disabling delaysof functions in the thermostat system.
 9. The thermostat system of claim7, wherein the diagnostics performed by the configuring device includeoverriding sensor inputs and set points of the thermostat system. 10.The thermostat system of claim 7, wherein the diagnostics performed bythe configuring device include testing sensors of the thermostat system.11. The thermostat system of claim 7, wherein the diagnostics performedby the configuring device include testing a cooling process and/or aheating process of the thermostat system.
 12. A thermostat systemcomprising: a plurality of thermostats, each thermostat comprising atleast one configuration for an air management system; and a thermostatof the plurality of thermostats can provide modulated control of an airmanagement system and discrete control of the same air management systemor another management system; and a sequencing system controllerconnected to the plurality of thermostats for controlling and stagingthe plurality of thermostats; and a configuring device; and wherein theconfiguring device may communicate with system sequencing controller,and the configuring device may upload one or more configurations of thesystem sequencing controller and/or at least one configuration of theplurality of thermostats, and execute diagnostics relative to thethermostat system.
 13. The thermostat system of claim 12, wherein: thethermostat system includes sensors, fan processes, cooling processes,and/or heating processes; and the diagnostics are executed relative toone or more of the sensors, fan processes, cooling processes, and/orheating processes.
 14. The thermostat system of claim 12, furthercomprising a modulated control for a simultaneous operation of a heatingdevice and a cooling device for affecting humidity.
 15. The thermostatsystem of claim 12, wherein the diagnostics include disabling delays offunctions in the thermostat system.
 16. The thermostat system of claim12, wherein the diagnostics include overriding sensor inputs and setpoints of the thermostat system.
 17. The thermostat system of claim 12,wherein the diagnostics include testing sensors of the thermostatsystem.
 18. The thermostat system of claim 12, wherein the configuringdevice may present diagnostic solutions.
 19. The thermostat system ofclaim 12, wherein each air management system has a plurality of zones.20. The thermostat system of claim 12, wherein the configuring devicecontains one or more configurations that may be downloaded to thethermostats.
 21. A thermostat system comprising: a configuring device;and a plurality of thermostats, each thermostat having at least oneconfiguration for an air management system; and wherein: the configuringdevice may upload one or more thermostat configurations and performdiagnostics on the configuration; and the diagnostics performed by theconfiguring device include disabling delays of functions in thethermostat system.
 22. A thermostat system comprising: a configuringdevice; and a plurality of thermostats, each thermostat having at leastone configuration for an air management system; and wherein: theconfiguring device may upload one or more thermostat configurations andperform diagnostics on the configuration; and the diagnostics performedby the configuring device include testing sensors of the thermostatsystem.
 23. A thermostat system comprising: a configuring device; and aplurality of thermostats, each thermostat having at least oneconfiguration for an air management system; and wherein: the configuringdevice may upload one or more thermostat configurations and performdiagnostics on the configuration; and the diagnostics performed by theconfiguring device include testing a cooling process and/or a heatingprocess of the thermostat system.
 24. A thermostat system comprising: aplurality of thermostats, each thermostat comprising at least oneconfiguration for an air management system; and a sequencing systemcontroller connected to the plurality of thermostats for controlling andstaging the plurality of thermostats; and a configuring device; andwherein: the configuring device may communicate with system sequencingcontroller, and the configuring device may upload one or moreconfigurations of the system sequencing controller and/or at least oneconfiguration of the plurality of thermostats, and execute diagnosticsrelative to the thermostat system; the thermostat system includessensors, fan processes, cooling processes, and/or heating processes; andthe diagnostics are executed relative to one or more of the sensors, fanprocesses, cooling processes, and/or heating processes.
 25. A thermostatsystem comprising: a plurality of thermostats, each thermostatcomprising at least one configuration for an air management system; anda sequencing system controller connected to the plurality of thermostatsfor controlling and staging the plurality of thermostats; and aconfiguring device; and wherein the configuring device may communicatewith system sequencing controller, and the configuring device may uploadone or more configurations of the system sequencing controller and/or atleast one configuration of the plurality of thermostats, and executediagnostics relative to the thermostat system; and further comprising amodulated control for a simultaneous operation of a heating device and acooling device for affecting humidity.
 26. A thermostat systemcomprising: a plurality of thermostats, each thermostat comprising atleast one configuration for an air management system; and a sequencingsystem controller connected to the plurality of thermostats forcontrolling and staging the plurality of thermostats; and a configuringdevice; and wherein: the configuring device may communicate with systemsequencing controller, and the configuring device may upload one or moreconfigurations of the system sequencing controller and/or at least oneconfiguration of the plurality of thermostats, and execute diagnosticsrelative to the thermostat system; and the diagnostics include disablingdelays of functions in the thermostat system.
 27. A thermostat systemcomprising: a plurality of thermostats, each thermostat comprising atleast one configuration for an air management system; and a sequencingsystem controller connected to the plurality of thermostats forcontrolling and staging the plurality of thermostats; and a configuringdevice; and wherein: the configuring device may communicate with systemsequencing controller, and the configuring device may upload one or moreconfigurations of the system sequencing controller and/or at least oneconfiguration of the plurality of thermostats, and execute diagnosticsrelative to the thermostat system; and the diagnostics include testingsensors of the thermostat system.
 28. A thermostat system comprising: aplurality of thermostats, each thermostat comprising at least oneconfiguration for an air management system; and a sequencing systemcontroller connected to the plurality of thermostats for controlling andstaging the plurality of thermostats; and a configuring device; andwherein: the configuring device may communicate with system sequencingcontroller, and the configuring device may upload one or moreconfigurations of the system sequencing controller and/or at least oneconfiguration of the plurality of thermostats, and execute diagnosticsrelative to the thermostat system; and the configuring device maypresent diagnostic solutions.